U.S. patent application number 11/881245 was filed with the patent office on 2008-05-08 for self-adhering waterproofing membrane.
Invention is credited to Dan Ben-Daat, Jon M. Jensen, Brian J. Whelan, Gary W. Whittemore.
Application Number | 20080104917 11/881245 |
Document ID | / |
Family ID | 40586719 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080104917 |
Kind Code |
A1 |
Whelan; Brian J. ; et
al. |
May 8, 2008 |
Self-adhering waterproofing membrane
Abstract
A membrane for application to a surface of a structure to
provide waterproofing protection to the structure, the membrane
including a surface layer of thermoplastic or elastomeric material,
a layer of cushion material sealed to the layer of thermoplastic or
elastomeric material, a pressure sensitive adhesive bound to a side
of the cushion material remote from the thermoplastic or
elastomeric material, and a release liner removably mounted on the
pressure sensitive adhesive.
Inventors: |
Whelan; Brian J.; (Canton,
MA) ; Whittemore; Gary W.; (Walpole, MA) ;
Ben-Daat; Dan; (Sharon, MA) ; Jensen; Jon M.;
(Sharon, MA) |
Correspondence
Address: |
Pandiscio & Pandiscio
470 Totten Pond Road
Waltham
MA
02451
US
|
Family ID: |
40586719 |
Appl. No.: |
11/881245 |
Filed: |
July 26, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60856155 |
Nov 2, 2006 |
|
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60934785 |
Jun 15, 2007 |
|
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Current U.S.
Class: |
52/408 ; 156/79;
427/208.4; 428/41.8; 52/746.1 |
Current CPC
Class: |
E04D 5/10 20130101; Y10T
428/2835 20150115; B29K 2101/12 20130101; B29C 66/72343 20130101;
C09J 2400/243 20130101; B29L 2009/00 20130101; B29C 65/10 20130101;
B32B 5/18 20130101; B29K 2309/08 20130101; B32B 7/12 20130101; B29C
66/43 20130101; B32B 2419/06 20130101; C09J 7/29 20180101; B29K
2077/00 20130101; B32B 2305/022 20130101; Y10T 428/1476 20150115;
B32B 27/08 20130101; B29K 2105/04 20130101; B29K 2067/00 20130101;
B29C 65/4825 20130101; B29C 66/71 20130101; B29C 66/7392 20130101;
Y10T 428/2848 20150115; C09J 2423/006 20130101; B29C 66/7212
20130101; B29C 66/727 20130101; B29C 65/5021 20130101; B29K
2995/0069 20130101; B29C 65/5042 20130101; B32B 2307/7265 20130101;
B32B 33/00 20130101; B29C 65/4895 20130101; B29C 66/1122 20130101;
B29K 2023/00 20130101; C09J 2301/162 20200801; B29C 66/7212
20130101; B29K 2309/08 20130101; B29C 66/71 20130101; B29K 2023/00
20130101; B29C 66/71 20130101; B29K 2077/00 20130101; B29C 66/71
20130101; B29K 2067/00 20130101; B29C 66/71 20130101; B29K 2027/06
20130101 |
Class at
Publication: |
52/408 ; 156/79;
427/208.4; 428/41.8; 52/746.1 |
International
Class: |
E04B 7/00 20060101
E04B007/00; B05D 5/10 20060101 B05D005/10; B29C 65/00 20060101
B29C065/00; B32B 33/00 20060101 B32B033/00 |
Claims
1. A membrane for application to a surface of a structure to
provide waterproofing protection to the structure surface, the
membrane comprising: an outer surface layer of a selected one of
thermoplastic and elastomeric waterproof material; a layer of
cushion material fixed to an inner surface of said layer of
waterproof material; a pressure sensitive adhesive bound to a side
of said cushion material layer remote from said layer of waterproof
material; and a release liner removably mounted on a side of said
pressure sensitive adhesive remote from said layer of cushion
material.
2. The membrane in accordance with claim 1, wherein said layer of
waterproof material is provided with selvedge structure
facilitating overlapping and bonding of the membrane to an
adjoining membrane of like construction.
3. The membrane in accordance with claim 1, wherein said layer of
cushion material comprises a cellular foam material.
4. The membrane in accordance with claim 1, wherein said pressure
sensitive adhesive layer retains adhesive properties in the
presence of water and concrete alkalis.
5. The membrane in accordance with claim 1, wherein said release
liner is manually separable from said pressure sensitive
adhesive.
6. The membrane in accordance with claim 1, wherein said outer
surface thermoplastic layer comprises at least in part a selected
one of vinyl and polyolefin.
7. The membrane in accordance with claim 1, wherein said surface
layer is at least about 0.015-0.080 inch in thickness.
8. The membrane in accordance with claim 1, wherein said layer of
cushion material is at least about 0.015-0.375 inch in
thickness.
9. The membrane in accordance with claim 3, wherein said outer
layer of waterproof material is bound to said layer of cushion
material by a selected one of adhesive adhering, laminating,
extrusion coating, heat sealing, gluing, and taping.
10. The membrane in accordance with claim 5, wherein said pressure
sensitive adhesive layer is adapted to be manually adhered to the
surface of the structure by the manual removal of said release
liner and placement of the adhesive layer on the surface of the
structure.
11. The membrane in accordance with claim 1, and further comprising
a barrier film disposed between said layer of cushion material and
said pressure sensitive adhesive.
12. The membrane in accordance with claim 6, wherein said surface
layer further comprises integral reinforcing material.
13. The membrane in accordance with claim 12 wherein said integral
reinforcing material comprises a selected one of glass fiber,
polyester, and nylon.
14. The membrane in accordance with claim 1 wherein said layer of
cushion material is adapted to conform around minor irregularities
in the surface of the structure, adapted to retain conforming
properties in the presence of water and alkalis, and adapted to
inhibit lateral water migration.
15. The membrane in accordance with claim 2, wherein the selvedge
structure is adapted to overlap the waterproof layer of the
adjoining membrane and to be secured thereto.
16. A method for making a waterproof membrane, the method
comprising the steps of: providing a layer of cushion material;
bonding a layer of waterproof thermoplastic or elastomeric material
to a first side of the layer of cushion material; affixing a layer
of pressure sensitive adhesive to a second side of the layer of
cushion material; and mounting a release liner on a side of the
pressure sensitive adhesive remote from the cushion material.
17. The method in accordance with claim 16, wherein the cushion
material comprises a cellular foam material of at least about
0.015-0.375 inch thickness.
18. The method in accordance with claim 16, wherein the layer of
waterproof material extends on a side thereof beyond a side edge of
adjoining cushion material of the membrane to form a selvedge, and
comprising the further step of bonding the selvedge to an edge
portion of an abutting layer of waterproof thermoplastic or
elastomeric material of a second membrane.
19. The method in accordance with claim 18, wherein the step of
bonding the selvedge comprises bonding the selvedge to the edge
portion of the abutting layer of thermoplastic or elastomeric
material of the second membrane by a selected one of adhesive,
glue, tape, and hot-air welding.
20. The method in accordance with claim 16, wherein the step of
bonding the layer of waterproof thermoplastic or elastomeric
material to the layer of cushion material comprises a selected one
of adhesively adhering, laminating, extrusion coating, heat
sealing, gluing and taping of the waterproof material to the
cushion material.
21-36. (canceled)
37. The membrane in accordance with claim 3 wherein said cellular
foam material comprises a non-absorptive closed cell foam.
38. (canceled)
39. The method in accordance with claim 16 wherein the cushion
material comprises a cellular foam material.
40. The method in accordance with claim 39 wherein the cellular
foam material comprises a non-absorptive closed cell foam.
41. The method in accordance with claim 16 wherein the
thermoplastic material comprises at least one of vinyl and
polyolefin.
42-47. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional
Patent Application No. 60/856,155, filed Nov. 2, 2006, and U.S.
Provisional Application No. 60/934,785, filed Jun. 15, 2007, both
filed in the names of Brian J. Whelan, Gary W. Whittemore, Dan
Ben-Daat, and Jon M. Jensen.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is directed to a self-adhering membrane which
may be applied to roof and/or wall structures, particularly "green"
roof and plaza deck constructions, including planters, balconies,
terraces, foundation walls, tunnel structures, and the like.
[0004] 2. Description of the Prior Art
[0005] It has become increasingly popular to provide new building
and other constructions with green roofs, that is, roofs supporting
earth, grass, and plantings, often with walk-ways and/or terraces.
The roof decks frequently are made of structural concrete or metal
decking covered with a rigid hardboard, sometimes metal-covered,
and covered with a water-proof thermoplastic membrane applied to
the outside surface of the concrete, rigid hardboard, or other
substrate. Inasmuch as the membrane is typically of the type
customarily used on conventional non-green rooftops, and having a
thickness of about 60 or more mils, the membrane must be applied to
a very smooth and clean concrete, rigid hardboard, or other rigid
surface. Irregularities in the smoothness of the outside surface of
the substrate can produce perforations and punctures in the
membrane which breach the water-tight integrity of the membrane.
The same problem applies to foundation walls, tunnel structures,
and the like, of structural concrete or masonry.
[0006] In an effort to better absorb and conform to irregularities
in the substrate surface, a layer of felt-like material has been
used to form a cushion layer of sorts between the substrate surface
and the waterproof membrane. However, it has been discovered that
while perforations and punctures in the membrane are reduced, any
that remain or occur allow water passing therethrough to flow into
the felt-like material which acts like a wick and spreads the water
out in directions not easy to determine. Because of lateral
migration of the water, a leak in the membrane in a first area may
make itself known in remote second areas. Determining the location
of the leak into the underlying structure can be extremely
difficult, expensive and time-consuming to accomplish, inasmuch as
removal of the overburden is required to gain access to a breach in
the membrane.
[0007] To overcome the above-noted problems, resort has been made
to adhered liquid materials, such as hot rubberized asphalt (HRA),
a system which, as the name implies, involves the laying down of
HRA in the form of a hot liquid, usually of about 150-215 mils
thickness. In such procedures, precautions must be taken with
respect to workers inhaling fumes, handling hot kettles, and the
hot asphalt. The odor and smell of asphalt tends to travel and
irritate nearby site workers, building occupants and general
public. Further, usually no portion of the area can be used during
installation of HRA nor after installation until the HRA cools and
solidifies.
[0008] Cold-applied liquid products are also used in such
applications, best installed in thinner coatings of around 60 mils
thickness. Such materials have fewer application issues inasmuch as
they are applied at ambient temperatures, but often contain
solvents which have odors and repugnant smells, or, when
spray-applied, produce air-borne particulates that create a
potential hazard for installers, site workers, and building
occupants.
[0009] Thus, there is a need for an effective, efficient, less
expensive, odor and solvent-free, and less hazardous material and
method for laying a waterproofing membrane down over a structure
that is subject to a wet or moist external environment.
[0010] Accordingly, an object of the invention is to provide a
waterproofing membrane for application to a surface of a structure
to provide waterproofing and moisture protection to the structure,
and which does not provide a medium for lateral migration of water
therethrough.
[0011] A further object of the invention is to provide a method for
making a waterproof membrane for application to a surface of a
structure.
[0012] A further object of the invention is to provide a roof/wall,
foundation or tunnel structure providing watertight integrity.
[0013] A still further object of the invention is to provide a
method for waterproofing a roof and/or a wall, foundation or tunnel
structure.
[0014] A still further object of the invention is to provide a
method for increasing puncture resistance of a thermoplastic
membrane for use in water proofing subterranean structures and
surfaces.
SUMMARY OF THE INVENTION
[0015] With the above and other objects in view, as will
hereinafter appear, a feature of the present invention is the
provision of a membrane for application to a surface of a structure
to provide waterproofing and moisture protection to the structure.
The membrane includes an outer surface layer of thermoplastic
material, a layer of cushion material laminated to, or fused to, or
adhered to, an inner surface of the layer of thermoplastic
material, a pressure sensitive adhesive bound to a side of the
cushion material remote from the thermoplastic layer, and a release
liner removably mounted on the remote side of the pressure
sensitive adhesive.
[0016] In accordance with a further feature of the invention, there
is provided a method for making a waterproof membrane, the method
comprising the steps of providing a layer of cushion material,
bonding a layer of waterproof thermoplastic material to a first
side of the layer of cushion material, affixing a layer of pressure
sensitive adhesive to a second side of the layer of cushion
material, and mounting a release liner on a side of the pressure
sensitive adhesive remote from the cushion material.
[0017] In accordance with a further feature of the invention, there
is provided a roof/wall, foundation or tunnel structure
(hereinafter "roof/wall") comprising a substantially rigid
substrate, and a laminar membrane adhesively bonded to an outer
surface of the substrate. The membrane comprises an outer surface
layer of thermoplastic material, a layer of cushion material bound
to an inner surface of the layer of thermoplastic material, and a
pressure sensitive adhesive bound to a side of the cushion material
remote from the thermoplastic layer, and bound to the
substrate.
[0018] In accordance with a still further feature of the invention,
there is provided a method for waterproofing a structural surface.
The method comprises the steps of providing a membrane for
application to the surface, the membrane comprising an outer
surface layer of thermoplastic material, a layer of cushion
material laminated to, or fused to, or adhered to an inner surface
of the layer of thermoplastic material, a pressure sensitive
adhesive bound to a surface of the cushion material remote from the
thermoplastic layer, and a release liner removably mounted on the
remote side of the pressure sensitive adhesive, removing the
release liner to expose the pressure sensitive adhesive, and
pressing the pressure sensitive adhesive against the structural
surface to conform the layer of cushion material to the structural
surface and bind the waterproofing membrane to the structural
surface.
[0019] In accordance with a still further feature of the invention,
there is provided a method for increasing puncture resistance of a
thermoplastic membrane for use in water proofing of subterranean
structural substrates. The method comprises bonding a layer of
cushion material to the thermoplastic membrane, the cushion
material comprising a cellular foam material, the cushion material
being adapted to conform around minor irregularities in a surface
of the structural substrate.
[0020] The above and other features of the invention, including
various novel details of construction, combinations of parts, and
method steps, will now be more particularly described with
reference to the accompanying drawings and pointed out in the
claims. It will be understood that the particular laminar
combinations and methods embodying the invention are shown by way
of illustration only and not as limitations of the invention. The
principles and features of this invention may be employed in
various and numerous embodiments without departing from the scope
of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Reference is made to the accompanying drawings in which are
shown illustrative embodiments of the invention, from which its
novel features and advantages will be apparent.
[0022] In the drawings:
[0023] FIG. 1 is a diagrammatic sectional view of one form of a
portion of a waterproofing membrane illustrative of an embodiment
of the invention; and
[0024] FIG. 2 is a diagrammatic sectional view of one form of a
portion of a waterproofed roof/wall structure illustrative of a
further embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to FIG. 1, it will be seen that the illustrative
waterproofing membrane 10 includes an outer surface layer 12 of
thermoplastic waterproof material, such as vinyl or polyolefin,
bonded to a cellular foam backing layer 14 coated with a pressure
sensitive adhesive 16. The bonding of the backing layer 14 to the
surface layer 12 may be accomplished by adhesive adhering,
laminating, extrusion coating, heat sealing, gluing or taping, or
the like. A manually removable release liner 18 is mounted on an
undersurface 17 of the pressure sensitive adhesive 16 prior to
application of the membrane 10 to a roof/wall structure 20 (FIG.
2).
[0026] The total composite membrane 10 may be about 120-140 mils or
greater, in thickness, including the layer of waterproof material
12, which may be about 60 mils, or greater, in thickness, and the
foam backing layer 14, which may be also about 60 mils, or greater,
in thickness. Alternatively, the layer 12 may be 0.015-0.080 inch
in thickness, and the backing layer 14 may be 0.015-0.375 inch in
thickness, depending upon the particulars of a specific application
or project.
[0027] The flexible foam backing 14 conforms around minor
irregularities in the roof/wall structure 20. The pressure
sensitive adhesive 16 provides a strong bond between the membrane
10 and the roof/wall structure 20, even in the presence of water
and concrete alkalis.
[0028] The structure 20 typically is a green roof and/or a plaza
deck serving as a roof structure for a work space or habitat
therebeneath. Because of the heavy loads associated with such
applications, the supporting deck 20 is most often structural
concrete. The external environment for such roofs is generally at
least damp and often subject to wetness, including pooling or
ponding. The structure may also be a foundation wall or an earth
sheltered structure or tunnel. The membrane 10 accordingly is
designed to protect the structure 20 from the effects of water
infiltration which can lead to structural deterioration and
interior water damage.
[0029] In one embodiment, the outer surface layer 12 is a
thermoplastic flexible sheet, made of vinyl or polyolefin, most
commonly with an integral reinforcing material, such as glass
fiber, polyester, nylon, or similar material. The backing layer 14
preferably is a cellular foam, such as a non-absorptive closed cell
foam. The backing layer 14 is provided with the pressure sensitive
adhesive 16 which is factory-applied and protected by the release
liner 18 which is removed during application. The laminar membrane
10 has been found to substantially increase puncture resistance,
compared to standard prior art membranes which do not include a
backing layer.
[0030] Preferably, the surface layer 12 extends beyond a side edge
22 of the foam backing layer by about 2-4 inches to provide a
selvedge 24. The membrane 10 is shown in width-wise cross section
in FIGS. 1 and 2 and is typically provided in rolls which are
6.5-12.0 feet in width with, additionally, the 2-4 inch selvedge 24
on one side. In positioning the membrane 10 on the structure 20,
the membrane sheets are disposed side-by-side with the foam backing
layers 14 tightly abutting each other, and with the selvedge 24
overlapping the top of an adjoining membrane. The selvedge 24 is
bonded, as by adhesives, glues, tapes, hot-air or solvent welding,
to the overlapped membrane surface layer to provide bonded seams
which will not deteriorate in the presence of water, moisture,
roots, micro-organisms, and the like.
[0031] There is thus provided a waterproofing membrane which can be
applied directly to concrete and other substances. The membrane
finds particular application to green roof, plaza deck, planter,
balcony and terrace substrates, foundation walls and tunnels, and
is highly resistant to sub-grade environments of constant dampness,
high alkalinity, exposure to plant roots, fungi, and bacterial
organisms, as well as hydrostatic pressure, including ponded water
conditions.
[0032] The membrane 10 is factory produced in its entirety. There
is no assembly of the membrane at the work site; even the adhesive
16 by which the membrane 10 is applied to the structural substrate
20, is provided on the membrane and protected until the point of
attachment by a readily removable release liner 18.
[0033] The membrane is made by providing the cellular foam backing,
or cushion layer 14, of a selected length and width suitable for
subsequent packaging in roll form. The layer of thermoplastic
waterproof material 12 is bonded to a first side of the cushion
layer 14. The layer of pressure sensitive adhesive 16 is deposited
on a second side of the cushion layer 14, and the release liner 18
is mounted on the pressure sensitive adhesive 16 to completely
cover the adhesive.
[0034] Preferably, the layer of thermoplastic waterproof material
12 extends beyond one side edge 22 of the cushion layer 14 to
provide the aforementioned selvedge 24.
[0035] In the event of any incompatibility between the cushion
material 14 and the pressure sensitive adhesive 16, a barrier film
26 may be interposed therebetween.
[0036] The assembled membrane components are then wound into roll
form suitable for placing on a substrate and unrolled on the
substrate, while manually removing the release liner 18 to place
the membrane 10, adhesive side down, on the surface of the
substrate 20.
[0037] Upon application of the membrane 10 to the substrate 20,
there is provided a roof/wall structure 30 (FIG. 2) including the
substantially rigid substrate 20 and the waterproof membrane 10
adhesively bonded to an outer surface of the substrate, the
membrane including the surface layer 12 of thermoplastic waterproof
material, the layer 14 of cushion material bound to the surface
layer 12, and the pressure sensitive adhesive 16 bound to a side of
the cushion material 14 remote from the layer of thermoplastic
waterproof material 12, and bound to the substrate 20.
[0038] The waterproof membrane surface layer 12 is in the form of
an elongated strip which extends sideways outwardly from the side
edge 22 of the layer 14 of cushion material to form the selvedge 24
(FIG. 1). The roof/wall structure includes a plurality of the
strips of membrane 10 disposed on the substrate 20 lengthwise
side-by-side with side edges 22 of their respective cushion
portions 14 abutting each other, and the selvedge 24 of one
elongated strip overlapping, and heat welded or otherwise adhered
to, the surface layer 12 of another elongated strip of like
structure.
[0039] The roof/wall structure thus formed is highly resistant to
the aforementioned sub-grade environments.
[0040] There is further provided a method for waterproofing a
structural surface. The method includes providing the waterproof
membrane 10 for application to the surface, the membrane comprising
the outer surface layer 12 of thermoplastic material, the layer of
cushion material 14 bound to an inner surface of the layer of
thermoplastic material, the pressure sensitive adhesive 16 bound to
a side of the cushion material 14 remote from the surface layer 12
of thermoplastic material, and the release liner 18 removably
mounted on the pressure sensitive adhesive 16.
[0041] The method includes the steps of removing the release liner
18 to expose the pressure sensitive adhesive 16, and pressing the
pressure sensitive adhesive 16 against the structural surface to
conform the layer of cushion material 14 to the structural surface
20 and bind the waterproofing membrane 10 to the structural
surface.
[0042] The method for waterproofing the structural surface further
comprises providing the layer 12 of thermoplastic material with a
selvedge 24 comprising an extension of the outer layer of
waterproof material 12 beyond a side edge 22 of the cellular foam
cushion 14, preferably by about 2-4 inches. The selvedge 24
overlaps a neighboring strip of membrane, while the cushion portion
14 of the two strips are in abutting relationship. The selvedge is
bound to the neighboring waterproof surface layer, as by
heat-welding, adhesively, and the like.
[0043] Finally, there is provided a method for increasing puncture
resistance of a thermoplastic membrane 10 for use in water proofing
of structural substrates 20, the method comprising bonding a layer
of cushion material 14 to the thermoplastic membrane 10, the
cushion material 14 comprising a cellular foam material, the
cushion material being adapted to conform around minor
irregularities in a surface of the structural substrate 20.
[0044] There is thus provided a membrane for application to a
surface of a structure to provide waterproof protection to the
structure, a method for making such a membrane, a roof/wall
structure including the membrane, a method for waterproofing a
structured surface using the aforementioned membrane, and a method
for providing increased puncture resistance to a thermoplastic
membrane.
[0045] It will be understood that many additional changes in the
details, materials, steps and arrangement of parts, which have been
herein described and illustrated in order to explain the nature of
the invention, may be made by those skilled in the art within the
principles and scope of the invention as expressed in the appended
claims.
[0046] For example, while the laminar structure described above is
said to include a waterproof thermoplastic layer, and while such is
regarded as a preferred embodiment, it will be apparent to those
skilled in the art that a waterproof elastomeric material could
also serve as a waterproof layer.
* * * * *