Waterproofing Membrane For Use on Inclined Surfaces

Abstract

The present invention provides a waterproofing membrane for use on inclined surfaces. The membrane is fabricated from one or more layers of flexible sheet material preferably consisting of woven or nonwoven synthetic polymers of polypropylene. A skid resistant pattern of polymer elements is applied to the top surface of the membrane. The polymer has a Tensile Modulus<15 MPa (ASTM D638, 23C, 50 mm/min), a Tensile Yield Elongation>50% (ASTM D538, 23C, 50 mm/min, and a Shore A Hardness (ASTM D2240, 23C, 0 sec)<90. In a preferred embodiment the polymer elements are made from polyvinyl chloride polymer with a Tensile Modulus<7 MPa (ASTM D638, 23C, 50 mm/min), a Tensile Yield Elongation>50% (ASTM D638, 23C, 50 mm/min, and a Shore A Hardness (ASTM D2240, 23C, 0 sec)<75. The pattern of polymer elements may be applied directly on the top surface of the membrane or produced on one side of a carrier sheet which is attached to the top surface of the membrane.

1 . A waterproofing membrane, said membrane fabricated from one or more layers of flexible sheet material and having a top surface and a bottom surface, and wherein a pattern of polymer elements is applied to the top surface of the membrane, wherein said polymer elements are made from a polymer material containing polyvinyl chloride and blends or copolymers thereof. 
     
     
         2 . A waterproofing membrane according to  claim 1  wherein said polymer elements have a Tensile Modulus<15 MPa (ASTM D638, 23C, 50 mm/min), a Tensile Yield Elongation>50% (ASTM D638, 23C, 50 mm/min, and a Shore A Hardness (ASTM D2240, 23C, 0 sec)<90. 
     
     
         3 . A waterproofing membrane according to  claim 2  wherein said polymer elements have a Tensile Modulus<7 MPa (ASTM D638, 23C, 50 mm/min), a Tensile Yield Elongation>50% (ASTM D638, 23C, 50 mm/min, and a Shore A Hardness (ASTM D2240, 23C, 0 sec)<75. 
     
     
         4 . A waterproofing membrane according to  claim 1 , wherein the height of the polymer elements is between 0.02 mm to 1.0 mm. 
     
     
         5 . (canceled) 
     
     
         6 . A waterproofing membrane according to  claim 4  wherein said pattern of polymer elements is comprised of distinct polymer regions having a density range of between 25 per 100 cm 2  to 2500 per cm 2 . 
     
     
         7 . A waterproofing membrane according to  claim 6  wherein the polymer elements can be discontinuous or interconnected, wholly or in part, to form the final pattern. 
     
     
         8 . A waterproofing membrane according to any one of  claims 1  to  7  wherein said pattern of polymer elements is applied directly on the top surface of the membrane. 
     
     
         9 . A waterproofing membrane according to any one of  claims 1  to  7  wherein said pattern of polymer elements is produced on one side of a carrier sheet which is attached to the top surface of the membrane. 
     
     
         10 . A waterproofing membrane according to  claim 9  wherein said carrier sheet is comprised of woven or nonwoven materials selected from the group consisting of synthetic polymers of polyethylene, polypropylene, polyethyleneterephthalate, and nylon, or blends and copolymers thereof; or glass or cotton, or blends thereof. 
     
     
         11 . (canceled) 
     
     
         12 . A waterproofing membrane according to  claim 10  wherein said one or more flexible sheets of material forming the membrane are selected from one or more of the group consisting of woven or nonwoven synthetic polymers of polyethylene, polypropylene, polyethyleneterephthalate and nylon, or blends and copolymers thereof; metal, woven or nonwoven glass, and bituminous materials. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . A waterproofing membrane according to  claim 9  wherein said carrier sheet is attached to the membrane layer by means of adhesive, ultrasonic, mechanical, or thermal bonding, or polymeric coating. 
     
     
         17 . A waterproofing membrane according to any one of  claims 1  to  16  wherein said pattern of polymer elements has a Coefficient of Friction (COF)>0.5 when tested under horizontal plane, saturated wet conditions as measured by an English XL VIT. 
     
     
         18 . (canceled) 
     
     
         19 . A waterproofing membrane according to  claim 18  wherein the pattern of polymer elements has a surface application weight of between 5 grams/m 2  and 50 grams/m 2 . 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . A waterproofing membrane according to any one of  claims 1  to  24  which has an exposed top surface solar reflectance>25% at 500 nm wavelength as measured by ASTM E903-96 on a black background. 
     
     
         26 . A waterproofing membrane according to any one of  claims 1  to  25  wherein said membrane is fabricated from one or more reinforced flexible sheets of material for use as a roofing underlayment. 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . A waterproofing membrane according to any one of  claims 1  to  15  wherein a coating layer comprised of high COF (>0.5 as measured in dry conditions by an English XL VIT) PP, PE, EVA, EMA, or copolymers and blends thereof, is extrusion coated to the bottom surface of the membrane. 
     
     
         30 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . A waterproofing membrane according to  claim 10  where the carrier sheet is attached to a reinforcing structural layer. 
     
     
         33 . A waterproofing membrane according to  claim 32  where said reinforcing structural layer is comprised of one or more layers of woven polypropylene, polyethylene, glass, nylon, polyethyleneterephthalate, metallic, or cotton fiber woven reinforcement or combination of any of them. 
     
     
         34 . A waterproofing membrane according to  claim 32  where said reinforcing structural layer is comprised of multiaxially oriented polypropylene, polyethylene, polyethyleneterephthalate, polyvinyl chloride, sheets or films, and blends and copolymers thereof. 
     
     
         35 . (canceled) 
     
     
         36 . (canceled) 
     
     
         37 . (canceled) 
     
     
         38 . A method of applying a pattern of polymer elements to a waterproofing membrane wherein a liquid-polymer formulation containing polyvinyl chloride and blends or copolymers thereof, is applied in a unsolidified liquid pattern to a top surface of said waterproofing membrane, then the unsolidified liquid pattern on the waterproofing membrane is cured at an elevated temperature. 
     
     
         39 . A method of applying a pattern of polymer elements in the form of a liquid-polymer formulation containing polyvinyl chloride and blends or copolymers thereof to a waterproofing membrane, wherein the polymer elements are first applied as an unsolidified liquid pattern to a carrier sheet of woven or non woven polypropylene (PP) or polyethyleneterephthalate (PET), then the unsolidified liquid pattern on the carrier sheet is cured at an elevated temperature and then the carrier sheet is attached to a waterproofing membrane made from one or more layers of flexible sheet material selected from one or more of the group consisting of synthetic polymers of polyethylene, polypropylene, polyethyleneterephthalate and nylon, or blends and copolymers thereof; metal, woven or non woven glass, and bituminous materials. 
     
     
         40 . A method according to  claim 38  or  39  wherein the carrier sheet with a pattern of polymer elements on its top surface is reinforced with a woven or non woven reinforcement layer comprised of woven or non woven polypropylene, polyethylene, glass, nylon, polyethyleneterephthalate, metallic, or cotton fiber reinforcement or combination of any of them. 
     
     
         41 . A method according to  claim 40  wherein the one or more layers of flexible sheet material forming the waterproofing membrane are polypropylene (PP). 
     
     
         42 . (canceled) 
     
     
         43 . A waterproofing membrane, said membrane fabricated from one or more layers of polypropylene and having a top surface and a bottom surface, and wherein a pattern of polymer elements is applied to one side of a non-woven polyester carrier sheet which is attached to the top surface of the membrane, wherein said polymer elements are made from a polymer material containing polyvinyl chloride and blends or copolymers thereof, wherein the height of the polymer elements is 0.20 mm and have a density of 800 per 100 cm 2 . 
     
     
         44 . A method according to  claim 21  wherein the pattern of polymer elements is applied by a rotary screen transfer roll. 
     
     
         45 . A method according to  claim 38  or  39  wherein the liquid-polymer formulation to be applied as an unsolidified liquid pattern is a paste containing polyvinyl chloride resin, a plasticizer, calcium carbonate, an epoxidised oil and a stabilizer, mixed to uniformity. 
     
     
         46 . A method according to  claim 39  wherein the pattern of polymer elements is applied by a rotary screen transfer roll.