U.S. patent application number 10/278254 was filed with the patent office on 2003-04-17 for fastening with wide fastening membrane.
Invention is credited to Banker, Shawn C., Provencher, Ronald L., Provost, George A., Tachauer, Ernesto S..
Application Number | 20030070391 10/278254 |
Document ID | / |
Family ID | 27394067 |
Filed Date | 2003-04-17 |
United States Patent
Application |
20030070391 |
Kind Code |
A1 |
Tachauer, Ernesto S. ; et
al. |
April 17, 2003 |
Fastening with wide fastening membrane
Abstract
A method of releasably fastening objects together includes
providing a first object with a continuous hook fastener membrane
having a base of thermoplastic resin and an array of hook fastener
elements formed contiguously with resin of one side of the base;
and releasably engaging complementary loop fastener elements of a
second object to the fastener elements of the first object. The
base of the fastener membrane is an wide and thin, permanently
stretched membrane of resin. The membrane is useful for roofing,
siding, insulating, flooring, ceiling installation and wall
coverings, for example.
Inventors: |
Tachauer, Ernesto S.;
(Bedford, NH) ; Provencher, Ronald L.;
(Manchester, NH) ; Banker, Shawn C.; (Lee, NH)
; Provost, George A.; (Litchfield, NH) |
Correspondence
Address: |
FISH & RICHARDSON PC
225 FRANKLIN ST
BOSTON
MA
02110
US
|
Family ID: |
27394067 |
Appl. No.: |
10/278254 |
Filed: |
October 23, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10278254 |
Oct 23, 2002 |
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PCT/US01/13752 |
Apr 26, 2001 |
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60199776 |
Apr 26, 2000 |
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60279498 |
Mar 28, 2001 |
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Current U.S.
Class: |
52/745.21 ;
52/506.05; 52/746.11; 52/747.1 |
Current CPC
Class: |
E04B 9/22 20130101; A47G
27/0437 20130101; F16B 2001/0028 20130101; E04B 1/7666 20130101;
A44B 18/0049 20130101; A47G 27/0475 20130101; E04D 5/143 20130101;
E04B 1/78 20130101; B29C 2043/465 20130101; A44B 18/0092 20130101;
B29C 59/025 20130101; B29L 2031/729 20130101; E04D 5/12 20130101;
E04D 3/3605 20130101; E04F 15/02138 20130101; E04D 5/147 20130101;
E04B 1/625 20130101; E04F 13/0882 20130101; E04H 15/32 20130101;
E04B 1/66 20130101; F16B 5/07 20130101; E04D 2001/3429
20130101 |
Class at
Publication: |
52/745.21 ;
52/747.1; 52/746.11; 52/506.05 |
International
Class: |
E04B 002/00; E04B
005/00; E04B 009/00; E04B 001/00; E04G 021/00; E04G 023/00 |
Claims
What is claimed is:
1. a method of releasably fastening objects together, the method
including: providing a first object with a continuous hook fastener
membrane having a base of thermoplastic resin and an array of hook
fastener elements formed contiguously with resin of one side of the
base; and releasably engaging complementary loop fastener elements
of a second object to the fastener elements of the first object;
wherein the base of the fastener membrane is a permanently
stretched sheet of resin having a width of at least two feet, a
length greater than its width, and a thickness of less than about
0.015 inch.
2. The method of claim 1 wherein the first object is a wall of a
building, the second object is a wall covering, the method
including securing the hook fastener membrane to the wall, and then
releasably engaging the complementary loop fastener elements of the
wall covering with the fastener elements of the hook fastener
membrane.
3. The method of claim 2 wherein the wall of the building is an
exterior wall and the wall covering is a siding material.
4. The method of claim 1 wherein the first object is a subfloor of
a building, the second object is a floor covering, the method
including securing the hook fastener membrane to the subfloor, and
then releasably engaging the complementary loop fastener elements
of the floor covering with the fastener elements of the hook
fastener membrane.
5. The method of claim 1 wherein the first object is a roof of a
building, the second object is a roof covering, the method
including securing the hook fastener membrane to the roof, and then
releasably engaging the complementary loop fastener elements of the
roof covering with the fastener elements of the hook fastener
membrane.
6. The method of claim 5 wherein the roof covering is a
shingle.
7. The method of claim 1 wherein the second object is a strap, the
method including covering an item with the hook fastener membrane
and then releasably securing the hook fastener membrane in place by
releasably engaging the complementary loop fastener elements of the
strap with the fastener elements of the hook fastener membrane.
8. The method of claim 1 wherein the first object-is a sheet of
insulating material, the second object is a building structure, the
method including securing the hook fastener membrane of the
insulating material to engageable loops disposed on the building
structure.
9. The method of claim 1 wherein the hook fastener membrane of the
first object is a vapor barrier and the second object is a building
structure, the method including securing the vapor barrier to the
building structure by releasably engaging the complementary loop
fastener elements of the building structure with the fastener
elements of the hook fastener membrane.
10. The method of claim 1 wherein the hook fastener membrane is
permanently stretched only in a direction corresponding to its
width.
11. The method of claim 1 wherein the thermoplastic resin of the
hook fastener membrane is biaxially oriented.
12. The method of claim 1 wherein the base layer has a thickness
less than about 0.005 inch.
13. The method of claim 1 wherein the hook fastener elements are
discretely molded hook-shaped projections.
14. The method of claim 1 wherein the hook fastener membrane has a
width of at least 5 feet.
15. The method of claim 1 wherein the fastener elements are present
at density of at least about 300 elements per square inch generally
over the one side of the base of the hook fastener membrane.
16. The method of claim 1 wherein the thermoplastic resin is
selected from the group consisting of polypropylene, polyethylene
terephthalate, polyethylene and nylon, copolymers thereof, and
compatible mixtures thereof with each other or with other
compatible materials.
17. The method of claim 1 wherein the plastic resin includes a
biocide or fungicide capable of preventing growth of biological
material such as mold or fungus.
18. The method of claim 1 wherein the plastic resin includes an
additive increasing absorption of ultraviolet light.
19. The method of claim 1 wherein the plastic resin includes a fire
repellant.
20. The method of claim 1 wherein the hook fastener membrane is
permeable to a selected environmental fluid such as water, vapor or
air.
21. A method of affixing a protective covering to a building
exterior, the method comprising: securing a hook fastener membrane
to the building exterior, the hook fastener membrane including a
base layer of thermoplastic resin and an array of hook fastener
elements formed contiguously of the thermoplastic resin of the
base, the hook fastener elements extending from a broad surface of
the base; and engaging complementary loop fastener elements of the
protective covering to the fastener elements of the hook fastener
membrane to releasably secure the protective covering to the
building exterior; wherein the base layer of the hook fastener
membrane is a permanently stretched sheet having a width of at
least two feet, a length greater than its width, and a thickness of
less than about 0.015 inch.
22. A method of affixing a decorative covering to a building
interior, the method comprising: securing a hook fastener membrane
to the building interior, the hook fastener membrane including a
base layer of thermoplastic resin and an array of hook fastener
elements formed contiguously of the thermoplastic resin of the
base, the hook fastener elements extending from a broad surface of
the base; and engaging complementary loop fastener elements of the
decorative covering to the fastener elements of the hook fastener
membrane to releasably secure the decorative covering to the
building interior; wherein the base layer of the fastener membrane
is a permanently width-wise stretched sheet having continuous
length, a width of at least two feet, and a thickness of between
about 0.001 inch and 0.015 inch.
23. A method of enclosing a space, the method comprising: providing
a hook fastener membrane including a base layer of thermoplastic
resin and an array of hook fastener elements formed contiguously of
the thermoplastic resin of the base, the hook fastener elements
extending from a broad surface of the base; providing a support
structure including complementary loop fastener elements; and
securing the hook fastener membrane to the support structure by
engaging the hook fastener elements with the loop fastener elements
to thereby enclose the space defined by the support structure;
wherein the base layer of the fastener membrane is a permanently
stretched sheet having a width of at least two feet, a length
greater than its width, and a thickness of less than about 0.015
inch.
24. A method of securing a protective cover about an object, the
method comprising: placing the protective cover about the object,
the protective cover including a hook fastener membrane including a
base layer of thermoplastic resin and an array of hook fastener
elements formed contiguously of the thermoplastic resin of the
base, the hook fastener elements extending from a broad surface of
the base; and securing the protective cover about the object with
straps having complementary loop fastener elements for engagement
with the hook fastener elements; wherein the base layer of the
fastener membrane is a permanently stretched sheet having a width
of at least two feet, a length greater than its width, and a
thickness of less than about 0.015 inch.
25. A method of removably securing a flooring material to a
subfloor, the method comprising: permanently attaching an
intermediate flooring layer to the subfloor, the intermediate
flooring layer having a base with a first broad surface and an
opposite, second broad surface, the first broad surface having a
dispersion of fastener elements available for engagement, the
second broad surface being disposed for attachment to the subfloor;
providing flooring material having an attachment surface and an
opposite flooring surface, the attachment surface bearing a
complementary loop fastener material engageable by said fastener
elements of said intermediate flooring layer; and releasably
engaging said complementary fastener material of said flooring
material with said fastener elements to removably secure the
flooring material to the subfloor; wherein the first broad surface
of the base and the fastener elements are formed integrally of the
same thermoplastic resin the first broad surface being a
permanently stretched sheet having a width of at least two feet, a
length greater than its width, and a thickness of less than about
0.015 inch.
26. The method of claim 25 wherein said intermediate flooring layer
further comprises a backing material laminated to said second
surface of said membrane for attachment to the subfloor.
27. The method of claim 26 wherein the step of permanently
attaching the intermediate flooring layer to the subfloor comprises
at least one of stapling, nailing or screwing.
28. The method of claim 26 wherein said backing material comprises
a dimensionally stable material, such as pressboard or foamed or
unfoamed plastic, such as polyvinyl chloride.
29. The method of claim 28 wherein the dimensionally stable
material has a plurality of parallel slits across its width to
provide flexibility and to allow the composite flooring fastener to
be rolled.
30. The method of claim 26 wherein the intermediate flooring layer,
with the backing layer laminated thereto, is in roll form.
31. The method of claim 25 wherein permanently attaching the
intermediate flooring layer to the subfloor further comprises
uncoiling the intermediate layer from a storage roll and
positioning the intermediate layer for attachment to the
subfloor.
32. The method of claim 25 wherein said flooring material comprises
tiles.
33. The method of claim 32 wherein said tiles have marginal
portions shaped for interlocking with adjacent like tiles to aid
tile alignment during installation and to avoid gapping between
adjacent tiles during use.
34. The method of claim 25 wherein said fastener elements have
stems of tapered profile, tapering outwardly from a relatively wide
base at the base layer to a smaller dimension and being of
thermoplastic resin integral with the base layer, the hook fastener
elements being exposed for engagement with complementary
hook-engageable material for securing to the membrane and being
present at density of between about 50 to 5000 fastener elements
per square inch generally over said first broad surface of the
membrane.
35. The method of claim 25 wherein the fastener elements are first
molded contiguously of the resin of the base and the base is then
permanently stretched.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT US01/13752, filed
Apr. 26, 2001, and also claims priority from U.S. provisional
applications 60/199,776 and 60/279,498, filed Apr. 26, 2000 and
Mar. 28, 2001, respectively.
BACKGROUND OF THE INVENTION
[0002] The invention relates generally to wide membranes, and
particularly to fastening objects together with such membranes.
[0003] As is known, membranes and other sheet and board materials
are incorporated in many different physical arrangements to protect
against a wide range of environmental conditions. Examples include
geotextiles to protect against water penetration or erosion, roof
membranes and building wrap materials to protect against rain and
wind, and membranes as well as sheet, batt and board materials that
serve as vapor barriers and sound barriers. Other environmental
products include thermal insulation for buildings and materials
used for outdoor shelters, tarpaulins, pallet wrap and packaging
materials, boat and machinery covers, plant covers and other covers
for agricultural use, and temporary covers over garbage dumps.
Generally, such products are cost-sensitive regarding manufacture
and the labor required to apply or secure them in place.
[0004] Previous work in the area of wide fasteners include U.S.
Pat. No. 6,035,498, and U.S. Pat. No. 5,945,131, the entire
contents of each of which are incorporated herein by reference as
if entirely set forth.
SUMMARY OF THE INVENTION
[0005] The invention features an environmental membrane which may
advantageously be of substantial dimensions in both length and
width, comprised of a base layer of thermoplastic resin and, over
at least one broad surface of the membrane, a dispersion of
fastener elements, e.g., hook and loop fastener elements, that are
available for engagement with complementary material for securing
to the membrane.
[0006] An important preferred feature of many aspects of the
invention is that the base layer of the membrane is in a
permanently width-wise stretched condition relative to its machine
direction (the machine direction being the direction of its
continuous production), in some cases the base layer being in a
stretched condition in both width-wise and length-wise directions,
and in some cases important cases being biaxially-oriented.
Preferred techniques for forming and stretching such base layer are
described in U.S. patent application Ser. No. 08/789,637, filed
Jan. 27, 1997, now abandoned in favor of U.S. Ser. No. 09/070,865,
filed Apr. 30, 1998, now U.S. Pat. No. 6,035,498 and U.S. Ser. No.
09/518,853, filed Mar. 3, 2000, all herein incorporated by
reference in their entirety. In most cases the base layer has a
thickness between about 0.001 inch and 0.015 inch, preferably less
than about 0.008 inch, while in some important instances the
thickness is less than 0.005 inch, in certain cases even less than
0.003 inch.
[0007] Depending upon the particular type of membrane and fastening
needs, the fastener elements are typically present at density of
between about 50 to 2000 fastener elements per square inch, the
fastener elements being distributed generally over the entire broad
fastening surface of the membrane, or over a margin or other region
at which attachment is desired. In important cases, the density of
the fastener elements is at least 300 fastener elements per square
inch.
[0008] In certain broad aspects of the invention the fastener
elements may be of any form provided in any manner, including
post-forming or post-molding after fabrication of the base sheet,
but in preferred cases the fastener elements are constructed for
hook and loop fastening, and are formed integrally with the base
sheet prior to stretching the base sheet.
[0009] In certain preferred embodiments the fastener elements are
of hook form, while in other cases the fasteners are of loop form,
or are secured fibers that function as loops.
[0010] Broadly, loop-engageable hook elements may be of mushroom,
palm tree or single or multi-directioned hook form, and may be
formed integrally with the sheet, or may be partially or fully
post-formed after the base sheet is fabricated. In certain
preferred embodiments the hooks are discretely molded elements,
formed simultaneously with the base sheet. In particularly
preferred embodiments of this aspect of the invention, hooks are of
tapered profile, rising from a wide base at the base sheet to a
relatively narrow loop-engageable crook.
[0011] Important embodiments of the above aspects of the invention
include one or more of the following features. The fastener or hook
elements are discretely molded elements, each preferably having a
profile, in the direction of primary loading or in certain cases,
in the machine direction, that is like the base of a pyramid
(pyramidal), rising by taper from a relatively wide profile base
that is integral with the common base layer of the membrane to a
narrower portion formed into a crook. The membrane has dimensions
of at least two feet in both length and width and in important
instances, dimensions of at least three feet or five feet or more
in length, width or both. The thermoplastic resin of which the
membrane and fastener elements is formed is selected from the group
consisting of polypropylene, polyethylene terephthalate,
polyethylene and nylon, copolymers thereof, compatible mixtures
thereof and compatible mixtures with other compatible materials
such as selected rubber and rubber-like materials. In important
instances the plastic resin includes a biocide or fungicide capable
of preventing growth of biological material such as mold or fungus,
or includes a U.V. absorber or other additive to protect the
membrane from deterioration or includes an insect or vermin
repellant. Also, in important instances the formed membrane is in a
post-treated condition, for instance, after forming, being rendered
permeable or semi-permeable to air or moisture vapor in the case of
building wrap or agricultural cover, or to water seepage, in the
case of geotextiles of the type constructed for soil retention
while capable of passing water.
[0012] In other products, according to the invention, the base
layer of the membrane is water impermeable, or impermeable to air,
or retentive of solids, or impenetrable or repellant to vermin or
so called "vector", referring e.g. to rodents, birds and insects
that may disturb the object being protected.
[0013] In cases where the fasteners are defined by loop material,
it is preferable that it comprise a needled and stretched non-woven
material formed, e.g., by the techniques described in U.S. patent
application Ser. No. 08/922,292, filed Sep. 3, 1997 or Ser. No.
09/262,159, filed Sep. 3, 1999 or Ser. No. 09/322,663, filed May
28, 1999, each of which is incorporated by reference. In some cases
the non-woven material is pre-stretched and laminated to a
pre-stretched plastic base layer; in other cases the materials are
laminated prior to final stretching, the stretching of the base
plastic layer serving to help form hook-engageable formations in
the fibers of the non-woven material.
[0014] According to one broad aspect of the invention, in a method
of releasably fastening objects together including (a) providing a
first object with a continuous hook fastener membrane having a base
of thermoplastic resin and an array of hook fastener elements
formed contiguously with resin of one side of the base; and (b)
releasably engaging complementary loop fastener elements of a
second object to the fastener elements of the first object; there
is an improvement (c) in which the base of the fastener membrane is
a permanently stretched sheet of resin having a width of at least
61 cm (2 feet), a length greater than its width and a thickness of
less than about 0.38 mm (0.015 inch).
[0015] Variations of this aspect of the invention can include one
or more of the following features. The first object is a wall of a
building, the second object is a wall covering, the method
including securing the hook fastener membrane to the wall, and then
releasably engaging the complementary loop fastener elements of the
wall covering with the fastener elements of the hook fastener
membrane. The wall of the building is an exterior wall and the wall
covering is a siding material. The first object is a subfloor of a
building, the second object is a floor covering, the method
including securing the hook fastener membrane to the subfloor, and
then releasably engaging the complementary loop fastener elements
of the floor covering with the fastener elements of the hook
fastener membrane. The first object is a roof of a building, the
second object is a roof covering, the method including securing the
hook fastener membrane to the roof, and then releasably engaging
the complementary loop fastener elements of the roof covering with
the fastener elements of the hook fastener membrane. The roof
covering is a shingle. The second object is a strap, the method
including covering an item with the hook fastener membrane and then
releasably securing the hook fastener membrane in place by
releasably engaging the complementary loop fastener elements of the
strap with the fastener elements of the hook fastener membrane. The
first object is a sheet of insulating material, the second object
is a building structure, the method including securing the hook
fastener membrane of the insulating material to engageable loops
disposed on the building structure. The hook fastener membrane of
the first object is a vapor barrier, the second object is a
building structure, the method including securing the vapor barrier
to the building structure by releasably engaging the complementary
loop fastener elements of the building structure with the fastener
elements of the hook fastener membrane.
[0016] Any of the variations of this aspect of the invention can
also include one or more of the following features. The hook
fastener membrane is permanently stretched only in a direction
corresponding to its width. The thermoplastic resin of the hook
fastener membrane is biaxially oriented. The base layer has a
thickness less than about 0.13 mm (0.005 inch). The hook fastener
elements are discretely molded hook-shaped projections. The hook
fastener membrane has a width of at least 1.5 meters (5 feet). The
fastener elements are present at density of at least about 300
elements per square inch generally over the one side of the base of
the hook fastener membrane. The thermoplastic resin is selected
from the group consisting of polypropylene, polyethylene
terephthalate, polyethylene and nylon, copolymers thereof, and
compatible mixtures thereof with each other or with other
compatible materials. The plastic resin includes a biocide or
fungicide capable of preventing growth of biological material such
as mold or fungus, or a U.V. absorbing additive or a fire repellant
or other repellant or agent to protect the membrane or objects with
which it is associated from deterioration or damage. The hook
fastener membrane is permeable to a selected environmental fluid
such as water, vapor or air.
[0017] In another broad aspect of the invention, a method of
affixing in a protective covering to a building exterior including
(a) securing a hook fastener membrane to the building exterior, the
hook fastener membrane including a base layer of thermoplastic
resin and an array of hook fastener elements formed contiguously of
the thermoplastic resin of the base, the hook fastener elements
extending from a broad surface of the base; and (b) engaging
complementary loop fastener elements of the protective covering to
the fastener elements of the hook fastener membrane to releasably
secure the protective covering to the building exterior. The base
layer of the hook fastener membrane is a permanently stretched
sheet having a width of at least 61 cm (2 feet), a length greater
than its width and a thickness of less than about 0.38 mm (0.015
inch).
[0018] In another broad aspect of the invention a method of
affixing a decorative covering to a building interior including (a)
securing a hook fastener membrane to the building interior, the
hook fastener membrane including a base layer of thermoplastic
resin and an array of hook fastener elements formed contiguously of
the thermoplastic resin of the base, the hook fastener elements
extending from a broad surface of the base; and (b) engaging
complementary loop fastener elements of the decorative covering to
the fastener elements of the hook fastener membrane to releasably
secure the decorative covering to the building interior. The base
layer of the fastener membrane is a permanently width-wise
stretched sheet having continuous length, a width of at least 61 cm
(2 feet) and a thickness of between about 0.025 mm (0.001 inch) and
0.38 mm (0.015 inch).
[0019] In another broad aspect of the invention, a method of
enclosing a space including (a) providing a hook fastener membrane
including a base layer of thermoplastic resin and an array of hook
fastener elements formed contiguously of the thermoplastic resin of
the base, the hook fastener elements extending from a broad surface
of the base; (b) providing a support structure including
complementary loop fastener elements; and (c) securing the hook
fastener membrane to the support structure by engaging the hook
fastener elements with the loop fastener elements to thereby
enclose the space defined by the support structure. The base layer
of the fastener membrane is a permanently stretched sheet having a
width of at least 61 cm (2 feet), a length greater than its width
and a thickness of less than about 0.38 mm (0.015 inch).
[0020] In another broad aspect of the invention, a method of
securing a protective cover about an object including (a) placing
the protective cover about the object, the protective cover
including a hook fastener membrane including a base layer of
thermoplastic resin and an array of hook fastener elements formed
contiguously of the thermoplastic resin of the base, the hook
fastener elements extending from a broad surface of the base; and
(b) securing the protective cover about the object with straps
having complementary loop fastener elements for engagement with the
hook fastener elements. The base layer of the fastener membrane is
a permanently stretched sheet having a width of at least 61 cm (2
feet), a length greater than its width and a thickness of less than
about 0.38 mm (0.015 inch).
[0021] In another broad aspect of the invention, a method of
removably securing a flooring material to a subfloor includes (a)
permanently attaching an intermediate flooring layer to the
subfloor, the intermediate flooring layer having a base with a
first broad surface and an opposite, second broad surface, the
first broad surface having a dispersion of fastener elements
available for engagement, the second broad surface being disposed
for attachment to the subfloor; (b) providing flooring material
having an attachment surface and an opposite flooring surface, the
attachment surface bearing a complementary loop fastener material
engageable by the fastener elements of the intermediate flooring
layer; and (c) releasably engaging the complementary fastener
material of the flooring material with the fastener elements to
removably secure the flooring material to the subfloor. The first
broad surface of the base and the fastener elements are formed
integrally of the same thermoplastic resin the first broad surface
being a permanently stretched sheet having a width of at least 61
cm (2 feet), a length greater than its width and a thickness of
less than about 0.38 mm (0.015 inch).
[0022] Variations of this aspect of the invention can include one
or more of the following features. The intermediate flooring layer
further comprises a backing material laminated to the second
surface of the membrane for attachment to the subfloor. The step of
permanently attaching the intermediate flooring layer to the
subfloor comprises at least one of stapling, nailing or screwing.
The backing material comprises a dimensionally stable material such
as pressboard or foamed or unfoamed plastic, such as polyvinyl
chloride. The step of permanently attaching the intermediate
flooring layer to the subfloor further comprises uncoiling the
intermediate layer from a storage roll and positioning the
intermediate layer for attachment to the subfloor. The flooring
material comprises tiles. The tiles have marginal portions shaped
for interlocking with adjacent like tiles to aid tile alignment
during installation and to avoid gapping between adjacent tiles
during use. The composite flooring fastener is in rolled form. The
dimensionally stable material has a plurality of parallel slits
across its width to provide flexibility and to allow the composite
flooring fastener to be rolled. The hook fastener elements have
stems of tapered profile, tapering outwardly from a relatively wide
base at the base layer to a smaller dimension and being of
thermoplastic resin integral with the base layer, the hook fastener
elements being exposed for engagement with complementary
hook-engageable material for securing to the membrane and being
present at density of between about 50 to 5000 fastener elements
per square inch generally over the first broad surface of the
membrane.
[0023] According to another broad aspect of the invention, a
water-impermeable roof membrane is provided which is constructed
and arranged to serve as an important structural element of
roofing, having a lower surface that has properties suitable for
being applied, directly or via an intervening layer, to a rough
roof. In important cases, a broad surface of the membrane that
bears hook or other fastener elements is adapted to be directed
upwardly, for engagement with compatible fastener material
associated with outer roof elements such as shingles, roof tiles or
exterior decking that overlie the roof membrane. In important
cases, the roof membrane is associated with waterproofing material
at its lower surface, for instance the roof membrane constituting,
or being provided with a layer of, waterproofing material or
adhesive. In important instances a pressure-sensitive adhesive
coating is provided upon the lower surface of the base layer of the
membrane (with or without an intermediate layer), the membrane is
rolled upon itself in a supply roll and the upper surface of the
fastener elements of the membrane is of substance and configuration
permitting releasable engagement with the pressure-sensitive
adhesive, or a release layer is interposed.
[0024] In another aspect, the invention features a roof membrane
comprising a base layer of thermoplastic resin, over at least one
broad surface of which is disposed a preferably wide dispersion of
discrete hook elements, the hook elements being of thermoplastic
resin integral with the base layer and available for engagement
with hook-engageable material for securing to the membrane, the
membrane having a lower surface having properties suitable for
being applied to a roof, and the broad surface of the roof membrane
being adapted to be directed upwardly, presenting upwardly-directed
hooks for securing engagement with loop material associated with
outer roof elements such as shingles, roof tiles or exterior
decking. Preferably this base layer comprises a permanently
width-wise stretched or a biaxially-stretched or oriented plastic
sheet. In particular embodiments the resin includes a biocide or
fungicide, and the membrane has a layer of waterproofing material
or pressure-sensitive adhesive adhered to its lower surface.
[0025] According further to the invention, an installed roof is
provided comprising a roof membrane of one of the forms described,
installed upon a roof structure, and outer roof elements such as
roof tiles, shingles or exterior decking having at least under
surface portions comprised of compatible fastener material are
engaged with fasteners of the upper surface of the roof membrane
for securing the roof elements in place.
[0026] In another aspect of the invention, a roof is provided
comprising a roof structure having a supporting surface carrying
roof elements such as roof tiles, shingles or exterior decking, a
fastener-bearing membrane is joined to either (1) the supporting
surface of the roof or (2) at least under-surface portions of the
roof elements, while a compatible fastener material having fastener
elements engaged by the fastener elements of the membrane is joined
to the other of the supporting surface or the undersurface portions
of the roof elements.
[0027] According to another broad aspect of the invention, an
exterior building wrap material is provided comprising a
fastener-bearing membrane which is permeable to moisture vapor but
impermeable to wind, the membrane being sized to be wrapped about
portions of a building and having fastener elements disposed to be
engaged by complementary fastener material to secure the wrap
material to other components of the building. In certain
embodiments, the exterior building wrap material has integral
fastener elements that are adapted to face inwardly of the building
to engage and be supported by complementary fastener material
previously fastened to the building structure. In these and other
important embodiments, the exterior building wrap material has
fastener elements adapted to face outwardly of the building for
engagement by complementary fastener strips for securing the wrap
material to the building or to complementary fastener material on
the inwardly facing surface of other building elements such as
insulation or wall board or exterior siding material, the building
wrap material supporting, at least in part, the other building
elements.
[0028] In another aspect, the invention features an exterior
building wrap membrane comprising a base layer of thermoplastic
resin, over at least one broad surface of which is disposed a
preferably wide dispersion of discrete hook elements, the hook
elements being of thermoplastic resin integral with the base layer
and available for engagement with hook-engageable material for
securing to the membrane, the membrane being impermeable to wind,
the hook elements being disposed to be engaged by loop material for
fastening. Preferably, the base layer of this building wrap
membrane comprises a permanently width-wise stretched plastic
sheet, in certain cases being a biaxially-stretched or
biaxially-oriented plastic sheet.
[0029] According further to the invention, a building at least
partially wrapped by an exterior building wrap material is provided
in which elements of the building wrap material dispersed over its
interior surface lie against sheathing of the building and define
therewith relatively isolated insulative air spaces, pockets or
cells. In these and other cases, a building is provided which is
wrapped by an exterior building wrap material according to the
invention in which fastener elements dispersed over the exterior
surface of the building wrap material face outwardly of the
building and are engaged by complementary fasteners on fastener
strips for securing the wrap material on the building, or by
compatible fastener material associated with the inner surface of
other building material such as siding or insulation or wall board
which is at least partially supported by fastener elements of the
membrane.
[0030] In another aspect of the invention, a building is provided
having its exterior surface at least partially covered by a
building wrap material, a membrane as described above either
serving the role of being secured to the exterior surface of the
building with fastener elements facing outwardly, or inwardly, or
both, and a complementary fastening material having fastener
elements engaged by the fastener elements of the membrane serves
the complementary fastening role not served by the membrane.
[0031] According to another broad aspect of the invention, an
insulation product is provided in which a fastener-bearing membrane
forms at least part of a surface or outer cover of a batt, or of a
portion of a roll, or a sheet or board of building insulation,
which may be thermal insulation or sound insulation, or both. The
insulation is disposed within a cover formed by the membrane or
laminated to the membrane, and the fastener elements of the
membrane are exposed on the exterior of the batt or portion of the
roll or sheet or board of insulation in regions engageable with
complementary fastening material disposed in stud, joist or rafter
cavities or against building surfaces for securing the batt or
portion of the roll or sheet or board of insulation in place.
[0032] In another aspect, the invention features a batt, roll,
sheet or board of building insulation adapted for heat or sound
insulation purposes, comprising insulation disposed within or
against an outer cover, the outer cover comprising, at least in
part, a base layer of thermoplastic resin and, disposed over at
least one broad surface of the membrane, a wide dispersion of
discrete hook elements. The hook elements are of thermoplastic
resin integral with the base layer and are available for engagement
with hook-engageable material for securing to the membrane. The
hook elements of the membrane are exposed on the exterior of the
batt, roll, sheet or board of insulation in regions engageable with
loop material disposed in stud, joist or rafter cavities or against
surfaces for securing the batt, portions of the roll, sheet or
board of insulation in place. Preferably, the base layer comprises
a permanently width-wise stretched plastic sheet, in certain cases
being a biaxially-stretched or a biaxially-oriented plastic
sheet.
[0033] In another aspect of the invention, an insulated structure
is provided comprising a batt, portion of a roll, sheet or board of
building insulation as described disposed between wall studs,
joists or rafters or against surfaces of a building structure and
engaged upon areas of complementary fastener material secured to
the studs, joists, rafters, or surfaces of other building
materials.
[0034] In another aspect, an insulated structure is provided,
comprising building surfaces or cavities defined by studs, joists,
rafters or building material, with batts or portions of rolls,
sheets or boards of building insulation disposed against the
surfaces or within the cavities, a membrane as described either
serving the role of a cover for the building insulation, or the
role of providing fastener surfaces of the cavities or surfaces, to
which the building insulation is secured, and a complementary
fastener material having fastener elements engageable by the
fastener elements of the membrane serves in the other fastening
role not served by the membrane.
[0035] According to another broad aspect of the invention, a
wallboard or panel is provided, which may be e.g., gypsum board,
wall board, blue board or insulation board, or a preformed wood or
synthetic panel comprising a planar member to at least one side of
which is joined a permanently width-wise stretched plastic sheet,
in some cases being a biaxially-stretched or a biaxially-oriented
plastic sheet having the features as described, preferably the
broad surface of the membrane carrying the fastener elements being
directed outwardly.
[0036] In another aspect, the invention features such a wallboard
or panel comprising a planar member to at least one side of which
is joined a membrane comprising a base layer of thermoplastic
resin, and disposed over at least one broad surface of the membrane
is a dispersion of discrete hook elements, the hook elements having
a tapered profile, tapering from a relatively wide base at the base
layer to relatively narrow crook portions, and being of
thermoplastic resin integral with the base layer and available for
engagement with hook-engageable material for securing to the
membrane, the broad surface of the membrane which carries the hook
elements being directed outwardly. In preferred embodiments, the
base layer comprises a permanently width-wise stretched plastic
sheet, in certain cases being a biaxially-stretched or a
biaxially-oriented plastic sheet.
[0037] Another embodiment is a wall board or building panel having
a planar surface to at least one side of which is joined a membrane
comprising a base layer of thermoplastic resin, over at least one
broad surface of the membrane there being a dispersion of
hook-engageable loops, the loops being directed outwardly,
available for engagement with hook for securing to the membrane. In
preferred embodiments, the base layer comprises a permanently
width-wise stretched or a biaxially-stretched or biaxially-oriented
plastic sheet. In preferred embodiments, the loop material is
provided by a needled nonwoven of staple fibers which subsequent to
needling, has been substantially stretched and bonded from the back
in that state.
[0038] According to another broad aspect of the invention, a wall
or ceiling covering is provided in the form of wallpaper, fabric,
paneling or insulation having a decorative side and an oppositely
directed side, and to the latter side is joined a permanently
width-wise stretched plastic sheet, in certain cases the sheet
being a biaxially-stretched or a biaxially-oriented plastic sheet,
the fastener elements of the sheet being directed inwardly for
attachment to a complementary fastener surface disposed on a
supporting wall or ceiling structure.
[0039] In another aspect, the invention features a wall covering
comprising wallpaper, fabric, paneling or insulation having a
decorative side and an oppositely directed side to the latter of
which is joined a membrane comprising a base layer of thermoplastic
resin. Disposed over at least one broad surface of this membrane is
a dispersion of discrete hook elements, the hook elements having a
tapered profile from a relatively wide base at the base layer and
being of thermoplastic resin integral with the base layer and
available for engagement with hook-engageable material for securing
to the membrane, the hook elements of the membrane being directed
inwardly for attachment to a loop surface disposed on a supporting
wall. In preferred embodiments the base layer comprises
biaxially-oriented plastic sheet.
[0040] In another aspect of the invention, a wall is provided which
is defined by an extended supporting surface carrying a wall
covering, and a permanently width-wise stretched or a
biaxially-oriented plastic membrane is joined to either (1) the
supporting surface of the wall or (2) the wall covering, while a
compatible fastener material engaged by the fastener elements of
the membrane is joined to the other of the supporting surface or
wall covering. In particular embodiments of this aspect of the
invention, the supporting surface comprises wallboard or a building
panel, and complementary membranes having features according to the
invention are on both of its sides.
[0041] Another embodiment of the invention is a wall defined by an
extended supporting surface carrying a wall covering. There is a
membrane having a base layer of thermoplastic resin, over at least
one broad surface of which is a dispersion of discrete hook
elements of profile that tapers outwardly from a relatively wide
base at the base layer, being of thermoplastic resin integral with
the base layer, these hook elements being available for engagement
with hook-engageable material for securing to the membrane. The
membrane is joined to either (1) the supporting surface of the wall
or (2) the wall covering, while a loop material capable of being
engaged by the hook elements of the membrane is joined to the other
of the supporting surface or wall covering. In preferred
embodiments the base layer comprises a permanently width-wise
stretched plastic sheet, in certain cases it being a
biaxially-stretched or a biaxially-oriented plastic sheet.
[0042] Another embodiment of the invention comprises an installed
ceiling defined by an extended supporting surface carrying a
ceiling covering comprising wall paper, fabric, ceiling tile or
ceiling sound or thermal insulation, and a permanently width-wise
stretched membrane, in certain cases being a biaxially-stretched or
a biaxially-oriented plastic membrane, is joined to either (1) the
supporting surface of the ceiling or (2) the ceiling covering,
while a compatible fastener material capable of being engaged by
the fastener elements of the membrane is joined to the other of the
supporting surface or ceiling covering. Complementary membranes
having features according to the invention may be respectively on
both of these surfaces.
[0043] Another embodiment is an installed ceiling defined by an
extended supporting surface carrying a ceiling covering comprising
wall paper, fabric, ceiling tile or ceiling sound or thermal
insulation. There is a membrane having a base layer of
thermoplastic resin, over at least one broad surface of which is a
dispersion of discrete hook elements of profile that tapers
outwardly from a relatively wide base at the base layer and being
of thermoplastic resin integral with the base layer, and available
for engagement with hook-engageable material for securing to the
membrane. The membrane is joined to either (1) the supporting
surface of the ceiling or (2) the ceiling covering, while a loop
material capable of being engaged by the hook elements of the
membrane is joined to the other of said supporting surface or
ceiling covering. In preferred embodiments the base layer comprises
a permanently width-wise stretched plastic sheet, in certain cases
being a biaxially-stretched or a biaxially-oriented plastic
sheet.
[0044] According to another broad aspect of the invention, a floor
membrane is provided comprising a permanently width-wise stretched
plastic membrane, in certain cases a biaxially-stretched or
biaxially-oriented plastic membrane, the floor membrane having a
lower surface that has physical properties suitable for being
joined to a subfloor (either directly or via an intervening layer),
the broad surface of the floor membrane being adapted to be
directed upwardly, presenting upwardly directed fastener elements
for engagement with complementary fastener elements associated with
a finished floor material such as ceramic, vinyl or cork tile, wood
flooring (in particular, hardwood flooring strips) or
carpeting.
[0045] In preferred embodiments a water-proofing material or
pressure-sensitive adhesive layer is joined to or forms part of the
membrane.
[0046] Another embodiment of the invention is a floor membrane
comprising a base layer of thermoplastic resin, over at least one
broad surface of which is a dispersion of discrete hook elements
having a profile that tapers outwardly from a relatively wide base
at the base layer and being of thermoplastic resin integral with
the base layer, the hook elements being available for engagement
with hook-engageable material for securing to the membrane. The
membrane has a lower surface having physical properties suitable
for being joined to a subfloor, and the broad surface of the
membrane is directed upwardly, presenting upwardly directed hook
elements for engagement with loops associated with a finished floor
material such as ceramic, vinyl or cork tile, wood flooring (in
particular, hardwood flooring strips) or carpeting. In preferred
embodiments the base layer comprises a permanently width-wise
stretched plastic sheet, in certain cases being a
biaxially-stretched or a biaxially-oriented plastic sheet.
[0047] In another embodiment, a floor comprises a subfloor, at
least one layer of water proofing material or adhesive substance is
adhered to the subfloor, and a membrane is secured or laminated to
the at least one layer of waterproofing material or adhesive
substance, the membrane comprising a permanently width-wise
stretched plastic sheet, in certain cases a biaxially-stretched or
a biaxially-oriented plastic sheet having its broad surface
carrying fastener elements directed upwardly, and the flooring
material having compatible fastener material on its under surface
engaged with fastener elements of the broad surface. In certain
preferred embodiments, the flooring material respectively comprises
ceramic tile, a composition tile such as vinyl or cork tile, a wood
flooring such as oak flooring strips, or carpeting. In certain
cases the floor is that of a tent, a sales booth, a commercial
display, a TV or movie set, a theatrical stage, or other temporary
or low-cost structure.
[0048] Another embodiment of the invention is an installed floor
comprising a subfloor, preferably at least one layer of
waterproofing material or adhesive substance adhered to the
subfloor, a membrane secured or laminated to the at least one layer
of waterproofing material or adhesive substance, or directly to the
subfloor the membrane comprising a base layer of thermoplastic
resin, over at least one broad surface of which is a dispersion of
discrete hook elements that have a profile that tapers from a
relatively wide base at the base layer and being of thermoplastic
resin integral with the base layer, the hook elements being
available for engagement with hook-engageable material for securing
to the membrane. The membrane has its broad surface carrying the
hook elements directed upwardly, and the flooring material has
hook-engageable loop material on its under surface engaged with the
hook elements of the broad surface. In preferred embodiments the
base layer comprises a permanently width-wise stretched sheet, in
certain cases being a biaxially-stretched or a biaxially-oriented
plastic sheet.
[0049] According to another broad aspect of the invention, a
protective membrane bearing a dispersion of fasteners, preferably
one component of a hook and loop fastening, is constructed and
arranged to form a flexible exterior cover impermeable to water,
such as rain or ground water. In certain embodiments, a flexible
exterior cover impermeable to water comprises a base layer of
thermoplastic resin, over at least one broad surface of which is a
dispersion of discrete hook elements of thermoplastic resin that
are integral with the base layer and available for engagement with
hook-engageable material for securing to the membrane. Preferably,
the base layer comprises a permanently width-wise stretched plastic
sheet, in certain cases being a biaxially-stretched or a
biaxially-oriented plastic sheet. In certain embodiments, the
exterior cover is in the form of a ground cover, typically black or
dark green, adapted to resist deterioration when exposed to sun
light. In certain cases, the exterior cover is constructed in the
form of a greenhouse cover or a roof material, the cover or roof
material being at least translucent, capable of transmitting a
substantial fraction of incident light. In certain cases a
greenhouse or other roof comprises one or more roof supports having
fastener material on the supports and two portions of membrane as
described. One of the portions of membrane comprises an exterior
layer, having its fastener elements directed inwardly, and engaged
upon an outer portion of the fastener material on the one or more
roof supports, while the other of the portions or membrane
comprises an interior layer, having its fastener elements directed
outwardly and engaged upon an inner portion of fastener material on
the one or more roof supports.
[0050] Another embodiment of the invention is a greenhouse or other
roof comprising one or more roof supports having loop material on
its exterior and two portions of membrane each comprising a base
layer of thermoplastic resin over at least one broad surface of
which is a dispersion of discrete hook elements of thermoplastic
resin integral with the base layer and available for engagement
with hook-engageable material for securing to the membrane. One of
the portions of membrane comprises an exterior layer, having its
hook elements directed inwardly, and engaged upon an outer portion
of loop material on one or more of the roof supports. The other of
the portions of membrane comprises an interior layer, having its
hook elements directed outwardly and engaged upon an inner portion
of loop material on one or more of the roof supports. In preferred
embodiments the base layer comprises a permanently width-wise
stretched or a biaxially-oriented plastic sheet.
[0051] Another embodiment of a fastener-bearing protective membrane
is a flexible exterior cover impermeable to water which is sized,
constructed and arranged as a tarpaulin, and which is associated
with straps comprised of compatible fastener material, the
tarpaulin or the straps at least being stretchy.
[0052] Other embodiments of flexible exterior covers having
fastener features as described include: a protective cover for
shrubs, trees, plant material, pallet loads or packages such as
gifts to protect the object covered during shipping or storage, the
protective cover sized and shaped to be wrapped about the object
and secured by compatible fastener material engaged upon the
fastener elements of the cover; a boat or vehicle cover comprising
the exterior cover sized and shaped to be wrapped about the boat or
vehicle and secured by loop material engaged upon the fastener
elements of the cover; the exterior cover sized and constructed as
an agricultural cover to cover agricultural objects such as the
ground around growing plants, protective cover for tobacco plants,
hay bales, straw stacks, ensilage, farm machinery, or earth; a
geotextile comprising an exterior cover of the type described,
sized and constructed for use in diverting or containing water or
preventing erosion or surrounding drain pipe as in a so-called
French drain installation; or a swimming pool cover sized and
constructed to cover a swimming pool.
[0053] Another embodiment of the invention comprises an upholstered
object of furniture or the like, an inner cover comprising a
membrane having fastener features as described, secured over the
object with the fastener elements directed outwardly, and an outer
material (such as finished upholstery fabric) having compatible
fasteners (such as loops of the fabric) directed inwardly and
engaged with fastener elements of the membrane generally over the
exterior of the object.
[0054] Another embodiment of the invention is a moving pad or
blanket comprising a broad layer of padding or filling and a cover
on the padding or filling, the cover comprising a membrane having
fastener elements as described, the fastener elements being exposed
to be engaged by compatible fastener elements for securing it in
place. In preferred embodiments, the moving pad or blanket includes
straps of compatible fastener material capable of engaging the
fastener elements of the moving pad or blanket, with at least the
membrane or the straps being stretchy.
[0055] Another embodiment is a moving pad or blanket comprising a
broad layer of padding or filling and, on the padding or filling, a
cover membrane comprising a base layer of thermoplastic resin, over
at least one broad surface of the membrane there being a dispersion
of discrete hook elements of thermoplastic resin integral with the
base layer and available for engagement with hook engageable
material for securing to the membrane, the hook elements of the
membrane being generally distributed over the exterior of the
object. Preferably the base layer comprises a permanently
width-wise stretched sheet, in certain cases being a
biaxially-stretched or a biaxially-oriented plastic sheet and
preferably the moving pad or blanket is associated with straps of
loop material capable of engaging the hook elements of the moving
pad or blanket, preferably at least the membrane or the loops being
stretchy.
[0056] In another embodiment, an insulation blanket comprises a
blanket of insulating material covered on at least one side with
the protective membrane comprising a base layer of thermoplastic
resin, over at least one broad surface of which is a dispersion of
discrete hook elements of thermoplastic resin that are integral
with the base layer and available for engagement with
hook-engageable material for securing to the membrane. Preferably,
the base layer comprises a permanently width-wise stretched plastic
sheet, in certain cases being a biaxially-stretched or a
biaxially-oriented plastic sheet.
[0057] According to another aspect of the invention, there is
provided a method of making a protective membrane product of
selected properties as described, which comprises continuously
forming a layer of plastic with integral molded projections by use
of a rotating mold roll, thereafter heating and stretching the
plastic layer at least width-wise to substantially increase the
width of the membrane and introduce molecular orientation, and
thereafter sizing, cutting and arranging the membrane so that it is
constructed and arranged to serve as the protective membrane
product, the steps of molding and stretching being cooperatively
related to provide the selected properties. In some cases, after
forming the membrane, it may be permanently stretched both
width-wise and length-wise. This stretching action may produce a
desired permanent biaxial orientation of the molecules of certain
resins, under certain conditions of treatment. The method of making
a membrane can employ any of the processes disclosed in the
following specification or in the prior U.S. patent applications
and patents which have been incorporated by reference.
[0058] Another aspect of the invention is the method of making a
protective or barrier membrane product of selected properties
comprising continuously forming a layer of plastic of selected
resin with integral projections by use of a rotating mold roll
having mold cavities of preselected dimensions, thereafter heating
and stretching the layer at least width-wise, substantially
increasing the width of the membrane, and thereafter sizing,
cutting and arranging the membrane into the form of the selected
product, the steps of forming and stretching being cooperatively
related to provide the selected properties.
[0059] Preferred embodiments have one or more of the following
features.
[0060] The method includes the step of treating the formed layer of
plastic to render it permeable to a selected degree.
[0061] The method includes punching the formed sheet, preferably
the punching being produced by electrical discharge punching, laser
punching, pin roll punching, needling or treatment of the sheet
with a beam of energetic electrons.
[0062] Other features and advantages will be apparent from the
following detailed description, claims, and attached drawings, and
from the disclosures of our prior U.S. patent applications and
patents which have been incorporated by reference above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] FIGS. 1 and 2 illustrate a method of fabricating a membrane
for products of the invention.
[0064] FIG. 3 illustrates a roofing material membrane.
[0065] FIG. 3A is a cross-sectional view taken along line 3A-3A of
FIG. 3.
[0066] FIG. 3B is a cross-sectional view similar to that of FIG. 3A
illustrating an alternate arrangement of the roofing membrane of
FIG. 3
[0067] FIG. 4 is a cross-sectional view of roofing shingles secured
to the roofing membrane of FIG. 3 that has been affixed to a roof,
while FIG. 4A is a magnified view of a portion of FIG. 4.
[0068] FIG. 5 is a cross-sectional view of one embodiment of a
roofing shingle.
[0069] FIG. 6 illustrates a membrane used to secure flooring
materials.
[0070] FIGS. 7, 7A and 7B diagrammatically illustrate methods of
fabricating composite flooring fasteners incorporating flooring
fastener membranes similar to that of FIG. 6.
[0071] FIG. 8 illustrates an alternate flooring fastener member
used to secure flooring materials.
[0072] FIG. 9 illustrates the flooring fastener member of FIG. 8
being used to secure flooring material to a subfloor.
[0073] FIG. 10 illustrates a flooring fastener composite in an
uninstalled, roll form.
[0074] FIG. 11 illustrates the flooring fastener composite of FIG.
10 in an unrolled state capable of receiving a mating flooring
material.
[0075] FIG. 12 illustrates an alternative embodiment of the
flooring fastener composite of FIG. 10.
[0076] FIG. 13 illustrates an apparatus and method for forming the
flooring fastener composites of FIGS. 10 and 12.
[0077] FIG. 14 illustrates a membrane used as a protective exterior
structural wrap.
[0078] FIGS. 15 and 15A are cross-sectional views of stages of
securing structural members to a hook-presenting membrane affixed
to a structure.
[0079] FIG. 16 illustrates a membrane used to install insulation in
a structure.
[0080] FIG. 17 is a cross-sectional view of a membrane used for
wallboards and insulation while FIG. 17A is a magnified view of a
portion of FIG. 17.
[0081] FIG. 18 illustrates a hook-bearing membrane used to secure
ceiling members.
[0082] FIG. 19 illustrates a membrane used to secure wall
members.
[0083] FIG. 20 illustrates a membrane used as a protective
tarpaulin.
[0084] FIG. 21 illustrates a membrane used in constructing a
shelter.
[0085] FIG. 22 is a cross-sectional view of one embodiment of a
support member for a shelter having the membrane of FIG. 21.
[0086] Like reference symbolism the various drawings indicate like
elements.
DETAILED DESCRIPTION OF EMBODIMENTS
[0087] As previously indicated, protective membranes of substantial
dimensions in both length and width carrying a field of fasteners,
are formed by stretching a thermoplastic sheet, preferably after
the hooks are molded integrally with the sheet or other fastener
elements are joined to the sheet.
[0088] A protective membrane with integral hooks and having
substantial dimensions in length and width, typically at least
about two feet to about five feet, and often much more is formed
generally according to the method disclosed in pending applications
U.S. Ser. No. 08/789,637, filed Jan. 27, 1997, U.S. Ser. No.
09/070,865, filed Apr. 30, 1998, now U.S. Pat. No. 6,035,498 and
U.S. Ser. No. 09/518,853, filed Mar. 3, 2000, which are
incorporated herein in their entirety. To briefly summarize,
referring to FIGS. 1 and 2, the membrane is preferably manufactured
by pulling sheet-form molten resin from the die lips of an
extruder, into a nip formed by two counter-rotating calendar rolls.
At least one of them is a mold roll, which defines over it surface
a field of tiny mold cavities e.g., of hook form suitable for hook
and loop fastening. At the nip an extended field of hook-form
fastener elements is molded on at least one surface of the thin
membrane that is formed by the calendar rolls. As shown in FIG. 2,
the sheet is then stretched width-wise up to 4 to 5 times its
original width to produce a membrane having biaxially-oriented
polymeric molecules, which provides strength to the stretched
membrane. With suitable choice of resin and thickness for the
particular application, the substantial width of the stretched
membrane that is achievable by the process allows it to be
constructed to serve as a protective barrier in the numerous novel
uses and structures described here.
[0089] The membrane includes a base layer typically comprising a
biaxially-oriented plastic sheet of thermoplastic resin. Depending
upon the application, the resin used may be homo polypropylene,
homo polyethylene terephthalate, homo nylon, and homo polyethylene,
and copolymers and/or mechanical mixtures of these polymers. The
resin is selected specially to achieve appropriate properties for
the novel product. For example, for ceiling members (as described
below), a polyethylene terephthalate resin may be preferred because
of its hardness and the strong hooks it forms, capable of
supporting vertical weight. For extremely wide membranes as used
where seams are undesirable, a polypropylene resin is preferred
because it is easy to stretch to great width. By choice of suitable
resin and thickness, the thermoplastic resin base layer of the
stretched membrane can act as a protective barrier that is
air-impermeable and water-impermeable, or with properties specially
tailored to the application.
[0090] Disposed over at least one broad surface of the membrane is
a dispersion of fastener elements, in many cases, preferably
discrete hooks for hook and loop fastening. As used herein, "hooks"
broadly includes any hooking element, e.g., hooks with crooks,
hooks of mushroom or palm tree shape, etc., that can engage with a
compatible loop material, for example, a nonwoven, needled-loop
material or a knitted or woven loop material. The hooks are
typically present at a density of between about 25 to 2,000 hooks
per square inch over at least one surface of the protective
membrane, depending on the application for the membrane. The hooks,
made of thermoplastic resin, preferably formed integral with the
base layer, are available to engage with hook-engageable material,
e.g., a layer of loops, for securing the material to the membrane.
Thus, not only can the membrane of the invention serve as a
fastener, but because of its substantial dimensions, the membrane
can also serve as a protective membrane, for example, against
water, air, pests, etc., with the added advantage of being able to
secure hook-engageable materials thereon.
[0091] Other examples of techniques for forming loop engageable
elements are those described in European patent application EP 0
852 918 A2 and subsequent corresponding patent publications, and in
WO/00/00053, text and drawings of which are hereby incorporated by
reference.
[0092] Where the protective membrane carries loop fastener
elements, it is advantageous that a film of thermoplastic resin be
formed by the well-known blown film method, to produce a biaxially
oriented film, which is then laminated to a needled non-woven which
has been extensively stretched, preferably biaxially, e.g., as
described in U.S. Ser. No. 08/922,292, filed Sep. 3, 1997, U.S.
Ser. No. 09/262,159, filed Mar. 3, 1999 and U.S. Ser. No.
09/322,663, filed May 28, 1994, all incorporated by reference in
their entirety. In other cases a preformed loop material can be
introduced with molten resin into the nip of a pair of calendar
rolls in which a plastic membrane is formed on the back of the loop
fabric or loop perform, the composite then being stretched
width-wise.
[0093] Generally, applications of the membrane of the invention are
directed to broad area covers. The membrane is typically placed on
an object with the hooks or other fasteners facing outward, away
from the object. In some applications, additional material, such as
shingles, having a mating layer, e.g., loop layer, secured to the
membrane by engaging the loop layer to the hooks of the membrane.
Depending on the application, the membrane is readily treated with
an adhesive to secure the membrane to the object and to provide an
added waterproofing layer. Additionally, the membrane or mating
layer can include a biocide or fungicide, to prevent growth of
biological material such as mold and fungus, or an ultraviolet
absorbing agent to protect the membrane from deterioration.
Specific novel products include but are not limited to, roofing
material, flooring material, building wrap, insulation wrappings,
ceiling material, wallpaper, tarpaulin, geotextiles, green house
roofs, upholstered objects, moving pads, blankets and insulation
blankets.
[0094] While only certain methods of fabricating the protective
membrane have been disclosed above, it should be recognized that,
within the broader aspects of the inventions protective membrane
disclosed can be fabricated by other methods. For example, these
methods can include extruding a sheet of molten plastic into a
roller nip or a narrow gap formed by a nozzle shaped about a roller
and subsequently stretching the sheet in both width and length
directions after forming (with or without molecular orientation).
Also the well-known "cut and stretch" method can be employed in
which parallel ribs of hook profile, formed integrally with a base
plastic layer, are repeatedly cut transversely without cutting the
base layer and the base layer is then stretched in the axial
direction of the ribs to separate the hook segments, as well as
width-wise to provide the needed length and width for the membrane
or sheet. Moreover, while the methods of application for the
membrane describe below suggest placing the membrane on the object
to be protected, it should be noted that, for appropriate
applications, the placement of the membrane and the loop layer can
generally be reversed, with the layer having loops disposed on the
object to be protected.
[0095] Whereas one aspect of the invention is, in general, the
concept of providing a novel protective membrane bearing a field of
fasteners, produced by the techniques disclosed, other aspects of
the invention concerns specific protective membranes and as well as
the systems of employing them and specific combinations of the
membranes with other elements that form novel end products and
usages.
[0096] Generally, a protective membrane and the object to be
secured to the hooks of the membrane can experience three types of
forces: tension, peel, and shear. According to the invention, these
properties are selected for a given membrane product, to accomplish
the novel function for which that product is uniquely designed. For
instance, ceiling coverings have hook fasteners that are
constructed to be especially strong under tensile forces to support
the attached ceiling tiles or other coverings. The hooks of roof
membranes are constructed to be especially resistant to peeling
forces, to securely attach roofing shingles. A wall-mounted
membrane for supporting tiles on vertical walls have fastener
elements especially constructed to be strong in shear, to support
the tiles vertically.
[0097] Generally, the size of the cooperating loops depends on how
much force the object will experience; and the size of the hooks is
related to the size of the loops. For example, ceilings tiles may
be secured with #24 hooks available from Velcro USA, Inc.,
Manchester, N.H., while wall tiles may be secured with #3905 hooks
available from Velcro USA, Inc.
[0098] Other special properties for specific membranes according to
the invention depend upon their novel application, including
thickness, width-wise stiffness and strength, color, and other
properties relevant to the novel application. For example, if the
membrane is used as a roofing material, the membrane may be black
to better accommodate the effects of sunlight while a membrane
specially constructed for a green house roof is typically
translucent to pass the sun's rays.
[0099] Roofing Membrane
[0100] Referring to FIG. 3, the membrane 100 comprises a protective
roofing material for a structure 110, such as a house or a
building. The base sheet of membrane 100 is constructed to be an
air-impermeable and water-impermeable protective barrier. It
carries a uniform field of molded hooks over its upper surface,
and, in the particular embodiment shown, an edge band of loop
material along at least one edge of the downwardly facing side.
This fastener hook-bearing underlayment is adapted for attaching
roofing shingles. Roof membrane 100 is typically provided on a
supply roll 105 and is rolled onto the roof 101, for example, like
tarpaper, to cover the entire roof with the hooks facing up and
away from the roof 101.
[0101] The membrane 100 can be affixed to the roof 101 by a number
of advantageous methods, or combinations thereof. In one example,
the membrane 100 is pre-coated on its bottom surface with a
pressure sensitive adhesive such as a rubber-based adhesive 113
that is compatible with the material of the roof 101, for bonding
to the roof. Such adhesives can be chosen such that the membrane
can be easily released when rolled upon itself, or a release sheet
may be interposed between successive layers of membrane in the
roll. Additionally, the adhesive can be selected to serve as an
added waterproofing barrier, further protecting the structure from
the effects of rain and wind. A sealing arrangement can be provided
by applying material having a layer of loops on one surface and a
layer of hooks on another surface, such as provided by strips 107
of FIG. 3A.
[0102] The membrane can also be mechanically affixed to the roof,
for example, by staples and nails, 111, FIG. 3B. The seams between
adjacent layers of membrane 100 can further be sealed with
over-lying sealing strips 107 that protect against leakage at the
locations of perforation points of the staples or nails.
[0103] Preferably the overlying sealing strips 107 have an
under-surface of hook-engageable loops, and an upper surface of
hooks, e.g., of density corresponding to that of the membrane 100.
The under surface can include an adhesive sealant material which is
penetrated by the hooks and forms a water-tight seal between the
base layer of the membrane 100 and the base layer of strip 107, to
complete the water-tight seal.
[0104] A self-joining strip 107 can be fabricated, for example, by
laminating a layer of loops to the back of a preformed hook
membrane. In another embodiment, material is introduced for forming
the loops, e.g., loose fibers, with the molten resin feed that
enters a forming nip, either by use of free fibers or a stretchy
loop-defining fabric. Using either of these methods, after forming
the base layer sheet with hooks on the opposite side at the forming
nip, the composite can be stretched to a very thin base thickness
since the layer of loop-forming fibers can stretch along with the
base layer.
[0105] In a low cost method of producing a roof membrane, only
outer edge margin of the back of a membrane is provided with loops,
as shown in FIG. 3. The central region of the back of the sheet can
carry, for example, a sealant or a tar paper layer, optionally
impregnated with fire retardant or sealant substance to provide
low-cost thickness and strength. The loop margin 109 of the sheet
is disposed at the region of overlap of successive courses of the
membrane, with the loops facing down to engage the hooks on the
lower membrane course. The resultant membrane has hooks facing up
throughout its entire extent to receive roofing elements, such as a
shingles, tiles, and decking, as described below.
[0106] The membrane 100 of FIG. 3 can advantageously be covered
with roofing elements such as a shingle 103, as shown in FIG. 4.
Each shingle 103 has a specially provided under-surface comprising
a layer of loops 104. Each shingle 103 is attached to the roof 101
by engaging the loops 104 of the shingle to the hooks of the
membrane 100 (and/or the strip 107) on roof 101.
[0107] In one preferred embodiment, as shown in FIG. 5, shingle 103
further includes a band of hooks 140 disposed on the lower margin
of the top surface of the shingle to be engaged by the layer of
loops on the lower margin of the under-surface of the overlapping
roofing element, see FIG. 4A. The band of hooks 140, typically 1 or
2 inches wide, thus better secures the exposed edge of the shingle
103. In this way the shingles 103 positioned on the roof 101, are
secured on their under-surface to the membrane 100 and to shingles
they overlap, and in turn assist in securing the further shingles
that overlap them.
[0108] In certain preferred embodiments of this aspect of the
invention, fungicide or biocide is incorporated in the substance of
the membrane or the loop material to protect the roof 101 from
organic growth.
[0109] Flooring
[0110] A flooring underlayment, in the form of a protective
membrane is especially fabricated to secure finished flooring
materials. The membrane carries hooks on its upper surface which
are constructed to be strong in peel and shear, and the stretching
of the membrane during its manufacture solves the problem of
achieving a wide field of molded hooks in an economically practical
manner in regard to cost of materials and the labor of placement.
Flooring materials that may be secured to this novel underlayment
include, but are not limited to, ceramic, vinyl and cork tiles;
parquet blocks; hardwood flooring; and carpeting. In FIG. 6, a
floor 201 is shown being completely covered with membrane 200,
which has a uniform field of hooks 202 facing upwardly, away from
the subfloor which is for example of concrete 206 or support beams
208. (FIG. 6 is suggestive of the hooks but does not show their
uniform dispersion over the entire floor which is the presently
preferred embodiment). The membrane 200 covering the floor offers
the advantages of sound insulation by providing a layer of air
space defined by the hooks and loops and a uniform cushioning
effect provided by the dispersion of upstanding hooks, e.g.
avoiding the hard sensation and sounds that poured concrete
subfloors 206 typically provide, see left side of FIG. 6. The
membrane 200 can be coated with a permanent, strong adhesive to
bond to the concrete 206 or plywood 208 subfloor material. The
membrane 200 can serve to waterproof the floor and may include in
its base layer additives that prevent fungi, mold, and other
organic growth. In one example, the membrane 200 (or a laminated
backing described below) includes a flame retardant additive to
resist the spread of flames across or through a floor employing
such a flooring membrane 200. Where temporary installation is
desired, the membrane 200 can be coated with a temporary adhesive
such that the flooring material and the membrane 200 can be easily
removed or it may be temporarily nailed or stapled. This feature is
useful for, e.g., a carpeted floor of a tent, a sales booth, a
commercial display, a television or movie set, or a theatrical
stage. The finished flooring materials 203, e.g., tiles or hardwood
flooring are provided with a layer of hook-engageable loops 204 on
their under-surface to engage with the hooks 202 of the membrane
200. When the flooring material is for instance a tile, the joints
between the tiles can be grouted directly on the membrane 200.
[0111] In an alternative embodiment, the width-wise stretched and
extended membrane underlayment provides an upwardly directed loop
surface, and hooks are provided on the under surfaces of the
finished floor elements.
[0112] Also, as described in previously incorporated U.S. Pat. No.
6,035,498, an added material can be laminated to the stretched
membrane on the side opposite the fastener members. After forming
and stretching the member, e.g., as described above with reference
to FIG. 1, the added material is laminated to the membrane. As
illustrated in FIGS. 7, 7A and 7B, the stretched membrane is heated
by heating unit 216 in such a manner that the fastener members are
not appreciably deformed. With the back surface 219 of the web of
the membrane in a heat-softened condition, added material 220 from
a source spool 222, or rigid added material 220' in flat stock form
(FIG. 7A) is brought into contact with the back surface of web 200
as the web is passed over a laminating roller 224 before being
spooled on takeup roller 226 or accumulated as a stack 226' of flat
sheets in the case of rigid added material 220'(FIG. 7B) for later
use. In the embodiment of FIG. 7, the web 200, under a degree of
tension, is trained about an arc of the laminating roll, which
thereby exerts pressure between the web back surface 219 and the
added material. As it cools and solidifies, web back surface 219
permanently adheres to added material 220 supplied from the
laminating roller, to form a two-sided product 228 that may be many
feet wide, with fastener members on one side and the added material
on the other side.
[0113] For novel flooring underlayments, the added material can be,
for example, a foam material which advantageously provides sound
absorption qualities to the installed floor and also offers
increased friction between the subfloor and the flooring membrane.
In another example, rigid added material 220' (FIGS. 7A and 7B) is
pressboard to provide support to the membrane and to provide a
stable surface for improved adhesion of the membrane to the
subfloor. In yet another example, rigid backing material 220' is a
foamed rigid plastic sheet, such as a foamed polyvinyl chloride
sheet sold commercially under the tradename "Sintra".TM..
[0114] In one embodiment, illustrated in FIGS. 8 and 9, a composite
flooring underlayment 300 is provided having a stretched membrane
302 with exposed fastener elements 304 and a laminated pressboard
backing 306. Composite flooring 300 is cut to a desired size and
shape and secured to subfloor 308, e.g., of wood, by for example,
staples 310. Tiles 312, e.g., of vinyl material, having fastener
element-engageable loop material 314 on one broad surface opposite
appearance surface 315 are provided for securement to composite
flooring underlayment 300. Each tile 312 has a male key feature 316
present along two marginal edges (one such edge shown) and a female
feature 318 present along two other marginal edges (one such edge
shown). With loop material 314 facing fastener elements 304 of
secured composite flooring 300, tile 312 is pressed against
composite flooring 3700. Fastener elements 304 engage loop material
314 to secure tile 312 in the desired position. A like tile 312'
having like features 316 and 318 is then pressed downward (in the
direction of arrow d of FIG. 9), interconnected with secured tile
312, and secured to composite underlayment 300. Interconnection
features 316 and 318 provide stability to maintain tight joints and
secure adjacent tiles to prevent gaps from forming. The tile
installation process is repeated until installation of the flooring
is complete.
[0115] Each tile is thus releasably secured to the flooring
underlayer and the flooring system provides easy installation, easy
flooring material, e.g., tile removal and replacement, easy repair,
e.g., removal and replacement of individual damaged tiles. The
composite flooring underlayer also provides a flooring moisture
barrier.
[0116] As described above, flooring fastener membranes of
substantial dimensions in both length and width carrying a field of
fasteners, are formed by stretching a thermoplastic sheet,
preferably after the hooks are molded integrally with the sheet or
other fastener elements are joined to the sheet.
[0117] In one example, as illustrated in FIGS. 10 and 11 composite
flooring fastener 400 having flexible support layer 409 disposed
between rigid backing 406 and stretched fastener membrane 402 is
provided in roll-form for ease of storage, shipping and use. Rigid
backing layer 406 is of a dimensionally stable, rigid material,
e.g., masonite, glass filled plastic, wood, filled or unfilled and
foamed or unfoamed thermoplastic or thermoset sheet, composites of
wood and virgin or recycled plastic or other materials with similar
properties.
[0118] Rigid backing layer 406 is slit laterally across its width,
the slit extending through the rigid backing layer 406, but not
extending through flexible support layer 909, which remains intact.
The slitting of backing layer 406 allows composite flooring
fastener 400 to be rolled in superposed form, as shown, despite the
relative rigidity of backing layer 406, i.e., as composite flooring
fastener material 400 is rolled, indvidiual slats 407 separate
along the outer circumference of each rolled layer, while remaining
attached in their relative positions to flexible support layer 409
along the inner circumference of each rolled layer. The separation
of individual slats along an outer roll layer circumference allows
rigid layer 406 to flexibly coil.
[0119] When composite fastener material 400 is unrolled, e.g.,
during installation to be fastened to a subfloor, spacing between
adjacent individual slats 407 is eliminated. In the unrolled, e.g.,
installed condition, individual rigid slats 407 abut each other
thereby supporting each other against any lateral loading that
might be experienced by flooring composite 400. Together,
individual slats 407 in their unrolled, abutting arrangement
provide support for the stretched fastener membrane 402, any
flooring material, decorative or otherwise, attached to membrane
402, and any loads experienced by the flooring material to prevent
undesirable buckling or wrinkling of the installed flooring
material. Additionally, if composite fastener material 400 is
attached, e.g., by staples, adhesives, nails, or otherwise, to an
associated underfloor, or if composite material constitutes a wall
to wall flooring underlayment whereby abutting walls offer lateral
support to the system, the rigid backing layer 406 in conjunction
with the engagement of fastener members 403 with mating fastener
material on an underside of the exposed flooring acts to prevent
any movement of the exposed flooring relative to the
underfloor.
[0120] Alternatively, fastener membrane 402 is an unstretched
fastener product having fastener elements extending from a base. In
this embodiment the base width, length, and thickness dimensions,
and the spacing between adjacent fastener elements remain
significantly unaltered after initial forming of the fastener
product shape.
[0121] In either case, intermediate flexible support layer 409 is
of, e.g., polyvinyl chloride, polypropylene, foamed polypropylene,
polypropylene compound, thermoplastic elastomers, olefinic
thermoplastic elastomers, thermoplastic polyurethane elastomers, or
other materials, in a foamed or unfoamed condition. Layer 409 is
provided to support stretched fastener membrane 402 (or an
unstretched fastener membrane) on one broad surface and to adhere
slit rigid backing material 406 on its opposite broad surface.
Flexible support layer 409 can also provide additional desirable
properties such as sound barrier, antibacterial/fungal treatment,
moisture barrier, or flame retarding characteristics, depending on
the material used and additives introduced or coatings applied.
[0122] Alternatively, as illustrated in FIG. 12, composite flooring
fastener 400' has slit rigid backing material 406 bonded directly
to stretched fastener membrane 402, i.e., intermediate flexible
support layer 409 is eliminated. In this embodiment, fastener
membrane 402 is of appropriate thickness after stretching to
provide the necessary support to slit rigid backing material 406 in
its flexed, rolled condition (FIG. 10) and in its unrolled,
installed condition (FIG. 6) to support flooring an attached
flooring material. As described above with reference to flexible
support layer 409, the properties of fastener membrane 402 can be
modified as desired by appropriate choice of material, additives,
coatings or any combination of these constituents.
[0123] Tri-layered laminate 400 can be produced by a modification
of the fastener membrane forming and backing layer laminating
processes described above with reference to FIGS. 1, 2, 7 and 7A.
As illustrated in FIG. 13, necessary modifications to the process
to form composite fastener 400 include lamination of intermediate
flexible support layer 409 to the non-fastener member bearing
surface 430 of stretched fastener membrane 402. Attachment of rigid
backing layer 406 to the exposed surface 432 of support layer 409
is achieved, for example, by an adhesive applied (e.g., by
supplying adhesive to be wiped on by roller 433) or lamination by
heat applied (e.g., by supplying heat through roller 433) to the
undersurface of support layer 409 prior to bringing exposed surface
432 into contact with rigid backing layer 406. Rigid backing layer
406 is subsequently slit, at slitting station 434, the slitting
being accomplished without severing support layer 409, to form
individual, flex-providing slats 407. In another embodiment,
intermediate support layer 409 and rigid backing layer are joined,
e.g., by an adhesive or by lamination, prior to attachment to
fastener membrane 402. The pre-joined rigid backing layer can be
slit prior to or after attachment of membrane 402 to intermediate
layer 409. In any of these embodiments, the tri-layered product 400
with slit rigid backing 406 is then wound into roll form as
illustrated at 436.
[0124] Alternatively, composite floor fastener 400', described
above with reference to FIG. 12, is produced by eliminating the
intermediate flexible support layer 409 and attaching rigid backing
layer 406 directly to non-fastener member bearing surface 430 of
membrane 402.
[0125] Composite flooring fastener 400 (or 400') can be wound into
roll-form for subsequent storage, shipping, and installation.
Installation of flooring fastener 400 is achieved by cutting
portions of adequate size and shape to fit a particular subfloor to
be covered. Each such portion is then attached by, e.g., staples,
glue, or other joining means, to the subfloor. In this manner,
multiple pieces of flooring fastener 400 can be cut to shape,
positioned, and adhered in an adjacent manner to completely cover a
subfloor. A temporary cover, e.g., a plastic film or sheet, can be
placed over the exposed fastener elements of flooring fastener 400
during installation to avoid unwanted engagement of the fastener
elements with, e.g., clothing of an installation worker or other
work materials that may come into contact with the fastener
elements. When the flooring fastener 400 is adhered in its desired
location, the protective cover is removed and a flooring material
having an attachment surface with fastener element engageable
backing material is removeably attached to the exposed fastener
element bearing surface of secured flooring fastener 400.
[0126] Building Wrap Material
[0127] A protective exterior structural wrap is shown in FIGS. 14,
15 and 15A. Similar to conventional building wrap material, such as
DuPont's Tyvek.RTM.), the membrane is used to wrap a structure as a
vapor-permeable, wind and water-impermeable protective barrier. In
this case, the base layer of the membrane, after formation, is
subjected e.g., to electrical discharge punching or other
pore-forming techniques that render the base layer vapor-permeable,
such as laser punching or drilling, pin roll punching, needling or
treatment of the sheet with a beam of energetic electrons or
ions.
[0128] A membrane placed upon a structure may have hooks facing
only away from the structure, with the membrane being secured
mechanically to the structure, e.g., by stapling, or by a
waterproof adhesive. However, in the case shown in FIG. 14, the
membrane 700 has loop-engageable hooks 702 formed on both sides of
the base layer. For securing the membrane to the building 701, the
inwardly facing hooks engage with strategically located loop strips
705 that have previously been secured to the building. Outer (or
inner) wall defining members 703, such as clapboard siding,
sheathing, or wallboard is attached to the outwardly directed hooks
702 of the membrane by hook-engageable loops 704 disposed on the
wall-defining members 703. As with the roofing elements, at
overlapping joints of the wall-defining members, a marginal band of
hooks may be provided to engage with the layer of loops on the
structural member that overlaps it.
[0129] In other embodiments, fields of hooks can be disposed on the
wall-defining members, and the building wrap membrane may provide a
field of loops with which the hooks of the wall-defining members
engage.
[0130] A further feature of the invention is that the engaged hooks
and loops define cells of isolated air space between the base layer
of the membrane and the structural or wall members, to provide
thermal or sound insulation.
[0131] Further Insulation Applications
[0132] Referring now to FIGS. 16, 17 and 17A, a membrane 900 is
used to install insulation into a structure while providing an
added air or moisture barrier, as previously generally described.
In one embodiment, a batt or a portion of insulation 901 is wrapped
with a membrane 900 that has hooks facing outwardly from the
insulation. The insulation may be a glass fiber batt, cellulose
insulation, particulate foam or a foam board. The membrane is
secured, e.g., laminated or glued, onto the exterior of the portion
of insulation 901 or formed as a sealed envelope containing the
insulation. The portion of insulation 901 is positioned into a
cavity defined by structural support members 908 such as studs,
joists, rafters, etc, that carry loop material 910. The insulation
is secured by engaging the hooks 902 of the membrane wrapper with
loop material 910 disposed on the support members. Alternatively, a
membrane carrying loop material can be provided on the outer wrap
of the insulation, and portions of a hook-bearing membrane can be
disposed on the support members.
[0133] The effect is to removably install the insulation in a
tight-fitting manner in a cavity, thus to prevent leaks of cold air
at the boundaries, etc.
[0134] In the embodiment of FIG. 9 a further membrane 900' has
loops 904 on its inner side which engage with hooks carried by the
insulation or by structural members. Membrane 900' also has hooks
902 on its outside. A wall board 903 or other wall covering having
loop material 904 on its inside surface is placed against the
membrane with the matching hooks and loops engaged to hold the wall
board or other covering in position.
[0135] Ceiling Installation
[0136] As shown in FIG. 18 a membrane 1100 is fabricated to secure
ceiling members 1103 such as tiles, sound-insulating bricks,
cellular material, fixtures, or paneling. As shown, the ceiling
1101 is covered with membrane 1100 that has uniform dispersion of
loop-engageable hooks 1102 facing downwardly, away from the
ceiling. The membrane can be secured to the ceiling, for example,
by using staples or adhesives, or by hook and loop engagement
between complementary hooks and loops provided on the upper surface
of the membrane and ceiling support members, respectively, or vice
versa with respect to the location of the hooks and loops.
[0137] In FIG. 18, the finished ceiling members 1103, having a
layer of loop material 1104 disposed on their upper surfaces, are
attached to the membrane 1100 by engaging the hooks 1102 of the
membrane with the loops of the finished ceiling members. Since the
weight of the ceiling members is entirely borne by the hooks and
loops, the hook and loop material preferably has high creep
resistance in the tensile direction to secure the ceiling members
to the ceiling. In preferred cases the base layer of the membrane
is in permanently stretched condition, as has been described.
[0138] Wall Coverings
[0139] As shown in FIG. 19, a stretched and preferably biaxially
oriented membrane 1200 is used to secure wall treatments 1203 such
as wallpaper (shown in Fig.), fabric or paneling. The wall
treatment materials are secured to a wall 1201 carrying membrane
1200 with the hooks 1202 of the membrane facing out from the wall.
The plastic membrane offers moisture proofing, an air movement
barrier, and added sound and thermal insulation. The wall treatment
material shown has a layer of loop material 1204 disposed on its
inner surface. The loop material itself can be chosen to provide
additional properties such as heat insulation, sound insulation,
soft feel, etc, while the dead air cells defined by the engaged
hooks and loops add to the insulating as well as a texturizing and
softening effect. The membrane may be affixed to the wall with
staples or an adhesive, for example. The adhesive can be temporary
or permanent, depending upon the application, and the adhesive can
be selected to provide additional waterproofing, organic growth
control, vermin and insect protection, etc. While the wall
treatment members are shown secured to the wall by engaging the
loops to the hooks, in an alternative embodiment, the loop material
can be carried on a stretched membrane disposed on the wall, and a
hook-bearing membrane can be provided on the inside surface of the
wall covering. In other embodiments a membrane may carry hook or
loop fastener elements on both surfaces, one side serving to secure
the membrane to the wall and the other side serving to secure the
wall covering. The systems described may be used advantageously to
mount temporary wall treatments, e.g., for theatrical stages or
sales booths and displays, and may be used to mount fabrics
carrying advertisements or decoration that can readily be changed.
For further features useful for this product see U.S. application
Ser. No. 09/322,663 which is incorporated by reference in its
entirety.
[0140] Outdoor Covers
[0141] As shown in FIG. 20, a membrane 1300 is constructed for use
as a protective tarpaulin, which is air-impermeable and
water-impermeable, and which provides the added benefit of easy
securement. The membrane can also be treated with or incorporate a
biocide or fungicide to resist organic growth. By virtue of the
stretching techniques described, the membrane can be manufactured
to a size large enough to cover large objects 1301 to be protected.
Such objects include, e.g., shrubs, trees, plant materials, boats,
vehicles, agricultural objects such as hay bales, straw stacks,
ensilage, farm machinery, earth or plants and swimming pools. These
objects are typically covered with the membrane 1300 having the
hooks 1302 facing toward the exterior, and strips 1303 of loop
material 1304 are suitably engaged with the hooks and supporting
structure to secure the tarpaulin to itself and/or around a pallet
or the protected object, as shown in the figure. In an alternative
embodiment the location of the hooks and loops is reversed.
[0142] Shelters Greenhouses and Tents
[0143] Referring to FIGS. 21 and 22, membranes 1500, 1500' are
constructed for use as a shelter such as a greenhouse or a tent.
The membrane is provided with sufficient thickness and strength to
span substantial distances between supports and to resist the
forces of storm-force winds and rains. It is constructed as a
protective barrier that is air-impermeable and water-impermeable,
though it may be provided with pores, as described above, to enable
transmission of water vapor. As shown in FIG. 22, in one
embodiment, the shelter is formed of a frame 1503 made of a rigid
material such as metal piping, PVC piping, etc. Disposed on the
exterior of the frame elements is loop material 1504. For example,
the loop material is wrapped around rigid pipes. Inner and outer
layers of membrane 1500 and 1500' are provided, typically of
transparent membrane, which are supported by the frame. The outer
membrane 1500 has its hooks facing toward the interior, to engage
with the loop material of the pipe supports to define the shelter,
e.g., a greenhouse. Additionally, the shelter can include the
additional layer 1500' of membrane to provide better thermal
insulation. In this case the hooks of the membrane 1500' directed
upwardly engage loops on the supporting pipes.
[0144] Geotextiles
[0145] In another embodiment, a membrane is constructed as a
geotextile or geomembrane. Typically, these are large sheets that
are used to retain soil against erosion, to confine water flows,
etc. In the prior art, typically adjacent sheets are joined
together by gluing, welding or stitching. By constructing a
geotextile or geomembrane according to the invention, strips of
loop material engage areas of hooks of adjacent membrane sheets to
hold them in place, or overlapping margins of adjacent membrane
sheets are provided with appropriately placed sections or bands of
hook and loop that are mated to join overlapping sheets together.
Additionally, adhesive strips covering the joints may be used to
keep the joints water-impermeable, or hook and loop strips 507
including sealant, such as disclosed in FIGS. 4A and 4B may be used
to seal the joints.
[0146] Other preferred features and configurations of fastener
material disclosed in our earlier U.S. patent applications,
incorporated by reference above, are useful in the construction of
the various products that have been described, and provide further
novel features.
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