Oil barrier waterproofing membrane laminate

Abstract: An improved pre-formed, flexible sheet-like laminate (10) suitable for waterproofing structural surfaces, comprising a flexible waterproof and waterproofing bituminous membrane (12) and, generally contiguous therewith, a non-removably adhered support carrier sheet assembly (14) which has been formed by co-extruding first and second polymeric layers (16,18) the outermost of which incorporates an additive for light reflectivity, and at least one co-extruded oil-resistant and oil-impermeable polymeric sheet (20).

Description: This invention relates to waterproofing materials which are in the form of pre-formed, sheet-like laminates of (a) a waterproof and waterproofing bituminous membrane adhered to (b) a support sheet material covering at least one major surface of the bituminous membrane. It is known that building surfaces, such as foundations, concrete decks, roofs, and the like, can be sealed in a waterproof manner by formation thereon of a continuous membrane of a bituminous composition that is substantially impermeable to moisture. The term "bituminous composition" as used in the present disclosure refers to compositions based on tar, asphalt or pitch with or without added components. Historically, such waterproofing membranes were formed by "in situ" application of a bituminous composition, along with one or more "plys" of bitumen-saturated felts. One disadvantage of this procedure is that the formation of a layer of waterproofing sealant at the job site was dependent upon uniform application. Such application caused additional expenses of labor at the job site. Moreover, vertical substructural membranes were often unmanageable. In more recent times, waterproofing of structural surfaces was done by using preformed, flexible membranes of bituminous compositions that were pressure-sensitive. These waterproofing materials had a laminate structure comprising a support sheet, such as a polymer film, adhered to a membrane of a flexible self-adhesive bituminous composition superimposed on the support sheet. As taught in Canadian Pat. No. 1,008,738 of Davis, it was known to employ in the support sheet a cross-laminated or biaxially-oriented synthetic polymeric film to avoid wrinkling after exposure to outdoor sunlight. In some applications, it is necessary to provide a reflective surface to minimise temperature gain due to solar exposure. While pigments could be incorporated into the polymer film, it was taught by Martin in GB 2,212,417 that this rendered the film tearable during the stretching operation which is part of the manufacturing process in the making of oriented films. Accordingly, Martin taught the use of a pigmented polymer layer which is coated onto the support sheet material by extrusion coating. The use of the pigmented polymer imparted a light color to the waterproofing laminate, so as to keep it cooler and reduce the temperature elevation in sunlight. In addressing the issue of solar heating, it is one purpose of the present invention to minimize the number of manufacturing steps required to provide a preformed waterproofing laminate membrane. Thus, the present invention is directed to membrane systems wherein a reflecting pigment coating is not separately coated in the process of forming the laminate membrane structure. Moreover, reflective pigments, which appear white or whitish in color, are sometimes discolored due to the migration of oils from the bituminous rubber adhesive layer. The use of oil-barrier layers in waterproofing laminate membranes is known, and can be referred to with respect to the issues just discussed above. For example, U.S. Pat. No. 4,396,665 of Rowe and No. 4,585,682 of Colarusso et al. teach the use of a thin layer of metal film to prevent migration of oils in the bitumen adhesive composition layer from reaching an uppermost polymeric support film. However, the use of the metal film is expensive, and presents thermal expansion issues which must be considered. Canadian Patent No. 1,145,109 of Hurst disclosed an oil-resistant polymer coating applied in liquid form between a first layer of bituminous self-adhesive composition and a second layer of bituminous composition which was substantially non-adhesive. The oil barrier coating prevented oil from one of the bituminous layers from migrating to the other layer. U.S. Pat. No. 4,442,148 of Stierli taught the use of an oil barrier coating layer which was located between a polymeric carrier sheet which might include a pigment such as carbon black and a bituminous adhesive layer. While an oil barrier film or coating material can indeed be employed within a multilayer waterproofing membrane composite to prevent discoloration of a white or whitish pigment, and in extreme cases to prevent bleeding-through of oil migrating from the bituminous adhesive layer, there is still the further problem of providing a laminate which can be assembled in a convenient, efficient, and cost-saving manner. It is desired herein to obtain a novel laminate which retains the kind of flexibility and manageability that might not be otherwise obtained through an excessively multi-layered or multi-coated structure, but which provides the desired durability in the face of rough job site demands, sunlight, and the elements. It is a purpose of the present invention to integrate in an effective, convenient, and cost-saving manner certain diverse properties, such as light-reflectivity to minimize thermal gain from sunlight, light absorptivity to minimize light transmission to the bituminous layer, and oil-barrier properties to prevent migration of oils which would stain a light reflective outer layer which is usually white or whitish in color. As will be further described herein, the present invention is directed to providing novel laminates in which an oil-barrier layer is used in conjunction with an incorporated additive that provides light reflectivity; and, according to the invention, one of the purposes is to provide both of these features in the same step so that they do not need to be separately applied. An additive for blocking the transmission of light (including ultraviolet light), such as carbon black, is further incorporated in a layer beneath the outermost layer which incorporates the light-reflective additive as just described. In an exemplary embodiment of the invention, a rollable, preformed membrane laminate for waterproofing structural surfaces, comprises a flexible waterproof and waterproofing self-adhesive bituminous membrane layer having oil therein: and a polymeric support carrier sheet structure non-removably adhered to said bituminous membrane layer said carrier sheet structure comprising a first outer polymeric layer, comprising an additive that is operative to reflect light, a second polymer layer co-extensive with said first layer and located between said first layer and said bituminous membrane layer and comprising a light absorbing additive, and at least one oil-resistant and oil-impermeable synthetic polymer film layer located between said carrier sheet first layer and said bituminous membrane layer. An exemplary method of the invention for fabricating a rollable waterproofing membrane laminate comprises the steps of: providing a carrier support sheet structure by providing a first outer polymeric layer incorporating an additive operative to reflect light; laminating said first polymeric layer to a second polymeric layer which is thereby co-extensive with said first layer and which comprises a light absorbing additive; and providing at least one oil-resistant and oil-impermeable synthetic polymer film layer by co-extruding a said oil-resistant and oil-permeable polymeric film layer with at least one of said first and second carrier support sheet layers; and providing a waterproof and waterproofing bituminous layer whereby said bituminous layer is non-removably attached to said carrier support sheet assembly on a side opposite said first polymeric layer. Further exemplary laminates and methods are described with further particularity hereinafter, with reference to the accompanying drawing in which:- Fig. 1 is a graphical illustration along a cross section of an exemplary bituminous waterproofing membrane laminate of the invention. As shown in Fig. 1, an exemplary waterproofing membrane laminate 10 of the invention comprises a self-adhesive, or pressure-sensitive, bituminous composition layer 12 which is generally contiguous with and non-removably adhered to a carrier support sheet assembly or structure 14. By the term "non-removably adhered," it is meant that the bituminous layer 12 cannot be removed from the carrier sheet assembly 14 without destroying the integrity of the bituminous layer 12 The bituminous adhesive composition 12 comprises a mixture of (a) a bituminous material and (b) natural or synthetic polymer, preferably a rubber or other elastomer polymer. The term "bituminous material" as used herein includes compositions containing asphalt, tar such as coal tar, or pitch. The bituminous adhesive may be reinforced with fibers and/or particulate fillers. In addition to any oils normally present in the bitumen, the adhesive composition may also contain a conventional extender component such as an aromatic oil. As aforementioned, the preferred polymer component is rubber which may be virgin rubber or a synthetic rubber (e.g., SBS, SBR) blended into the bitumen, and preferably, extender oil at an elevated temperature, to form a smooth mix. The bituminous adhesive layer 12, at least at its surface remote from the carrier support sheet 14 is, as mentioned, preferably pressure-sensitive and tacky at normal ambient temperature in order that it be self-adhesive to the substrate surface (e.g., foundation, concrete deck, roof). The bituminous layer 12 serves to form a continuous waterproofing layer which is elastic and self-sealing against punctures at high and low temperature. Preferably, the thickness of the bituminous layer 12 is in the range of 10 to 200 mils (0.254 to 2.54 mm) thick, and more preferably is about 30 to 60 mils (0.762 to 1.524 mm) thickness. The support carrier sheet assembly or structure 14 serves as a strength imparting and supporting member within the laminate 10 and as a barrier to prevent moisture vapor transmission through the laminate. Preferably, the thickness of the carrier sheet assembly 14 is less than that of the bituminous waterproofing adhesive layer 12. However, the carrier sheet assembly 14 should be of sufficient thickness to impart tear- and puncture-resistance to the laminate 10. The carrier sheet assembly 14 should preferably have a thickness of about 1 to 50 mils (.001 to .050 inches) (0.0254 to 0.127mm). The carrier sheet assembly 14 comprises a first polymeric layer 16 and a second polymeric layer 18 which may be laminated to this first layer 16. The dimensional stability of these two layers 16 and 18 can be, and are typically, adversely affected by oils present in the bituminous membrane 12, especially when the laminate 10 is exposed to elevated temperatures as may be experienced in roof top environments.. The first and second layers 16 and 18 may be comprised of a polyolefin film such as polyethylene, and the film may be uniaxially oriented, biaxially-oriented or cross laminated, as is known in the art. In the present invention, the first carrier sheet layer 16, which is located on the side of the second carrier sheet layer 18 opposite the bituminous layer 12, further comprises at least one additive operative to reflect visible light. Preferably, the additive 17 imparts a white or whitish color to the first polymeric layer 16. The additive can be selected from the group consisting of titanium dioxide, calcium carbonate, and zinc oxide. Titanium dioxide is preferred. At least one oil-resistant and oil-impermeable synthetic polymer layer 20, as may be known in the art, is located between the first layer 16 and bituminous layer 12. In a preferred method for making the second polymer layer 18, at least one oil-impermeable synthetic polymer layer film 20 is co-extruded with the second polymeric layer 18. If only one oil-impermeable polymeric layer 20 is co-extruded with the second polymer layer 18, the oil-barrier layer 20 side can be positioned such that it is located between the first 16 and 18 carrier sheet layers or between the two layers 16/18 and the bituminous layer 12. In another embodiment, the oil-impermeable polymeric layer 20 can be co-extruded with the first layer 16, and positioned such that it resides between the two polymeric carrier layers 16 and 18 then they are laminated together. In another exemplary embodiment, at least one oil-impermeable barrier film layer 20 can be co-extruded with each of the two carrier sheet layers 16 and 18. A number of possibilities are envisioned, and each is contemplated within the scope of the present invention. Thus, a carrier sheet structure 14 can have an oil-impermeable barrier or layer 20 located between each of the layers 16, 18, and 12 by coextruding an oil-impermeable film layer with each of said first 16 and second 18 polymer layers, or by co-extruding an oil-impermeable layer on the opposing sides of the second polymer carrier layer 18. In further exemplary embodiments, an oil-barrier film 20 can be extruded on each of the first 16 and second 18 polymeric film layers and located on opposing sides of those two layers 16/18. One or more oil-barrier film layers 20 can, of course, be located between the first 16 and second 18 polymer layers. Further exemplary embodiments comprise an oil barrier film layer 20 located on both sides of each of the first and second polymer sheet layers 16 and 18. The advantage of locating one or more oil-impermeable layers 20 in a symmetrical fashion within the carrier sheet assembly 14 is to increase dimensional stability over time. The oil-resistant polymeric layer 20 can be any known polymeric material which is capable of acting as an oil passage barrier with respect to the support sheet member, and in particular the outer-most first polymeric layer 16. Suitable oil-resistant polymer layer 20 materials can comprise a material such as a polyamide, a polyethylene terephthalate, a polyvinyl acetate, a polyvinylidene chloride, and other co-extrudable film materials that might be known in the film packaging arts. The polymer 20 material can also contain additives to improve its properties. A light absorbing additive, as may be known in the coating arts, preferably such as carbon black, is incorporated into the polymer which is extruded to ford the second polymeric support sheet layer 18 and optionally also any oil-impermeable barrier layer 20 located beneath the top first layer 16 and the bituminous layer 12. Accordingly, the first polymeric layer 16 contains a light reflective additive such as titanium dioxide, such that it reflects light and reduces solar thermal gain, while the second carrier sheet layer 18 and optionally an oil-resistant barrier layer 20 (located such as adjacent the bituminous layer 12 and/or between the first polymer layer 16 and the bituminous layer 12) contains a light-absorptive material, such as carbon black, to minimize transmission of solar energy to the bituminous layer 12. The light-absorptive material 19 is operative to block visible or ultra-violet light from reaching the bituminous composition 12 when the waterproofing laminate 10 is installed on the substrate surface (not shown) to be protected. The advantages of the novel selection and arrangement of components described herein is to lower thermal gain from sunlight, to improve thereby the dimensional characteristics of the laminate, especially in southern climates, and to eliminate the migration of oils, especially aromatic oils, into the film composite which would otherwise cause loss of reflectivity and have deleterious effects on dimensional stability. Furthermore, the solar effects on the bituminous compound are minimized due to decrease light transmissivity in the laminate. Preferably, although not necessarily, where more than one oil-impermeable polymeric layer 20 is used, the support carrier assembly 14 should employ such layers in a symmetrical arrangement to minimize curling or other deformation due to the use of different materials in the first and second layers 16/18 and in the oil-impermeable polymeric layer 20. For example, the waterproofing membrane laminate 10 may contain a carrier sheet assembly 14 comprising first and second sheet layers 16 and 18, laminated together, each of which is formed by co-extruding between two polyethylene films an oil-impermeable polymeric film. A tie coat adhesive as will be known to those in the art may be used to adhere the two polyethylene layers coextruded with the inner oil-impermeable layer. A further advantage of the invention is to provide convenient and cost-effective methods for fabricating the waterproofing membrane laminate 10. Accordingly, one exemplary method for fabricating the waterproofing membrane laminate 10 comprises the steps of providing a carrier support sheet assembly 14 by providing a first polymer film 16 incorporating an additive 17 operative to reflect light, laminating said first film 16 to a second film 18 which is generally co-extensive with said first film 16; providing at least one oil-resistant and oil-impermeable polymeric film 20 by coextruding said polymeric film 20 with at least one of said first 16 and/or second 18 carrier support sheet layers; and providing a waterproof and waterproofing bituminous layer 12 whereby said bituminous layer is non-removably attached to said carrier support sheet assembly 14 on a side opposite said first polymer film 16 incorporating said light reflecting additive 17. The co-extrusion of said oil-impermeable layer is indeed of structural and process significance when one takes into account the extra sequentially necessitated step of otherwise laminating two separate layers together using a compatible adhesive. Further exemplary methods comprise the step of incorporating a light absorptive material 18, preferably carbon black, into either or both of said second carrier sheet layer 18 and/or at least one oil-impermeable layer 20, prior to extrusion of said layers 18/20.. As modifications and equivalents may appear evident to those skilled in the art in viewing the disclosure herein, the scope of the invention is not intended to be limited by any of the exemplary or preferred foregoing embodiments, which are provided for illustrative purposes only.

Claims: A rollable, pre-formed membrane laminate (10) for waterproofing structural surfaces, comprising:- a flexible waterproof and waterproofing self-adhesive bituminous membrane layer (12) having oil therein: and a polymeric support carrier sheet structure (14) non-removably adhered to said bituminous membrane layer (12) said carrier sheet structure (14) comprising a first outer polymeric layer (16), comprising an additive that is operative to reflect light, a second polymer layer (18) co-extensive with said first layer and located between said first layer (16) and said bituminous membrane layer (12) and comprising a light absorbing additive, and at least one oil-resistant and oil-impermeable synthetic polymer film layer (20) located between said carrier sheet first layer (16) and said bituminous membrane layer (12). A waterproofing membrane laminate according to claim 1 wherein said at least one oil-resistant polymeric film (20) is co-extruded with at least one of said first or second carrier sheet polymeric layers (16,18). A waterproofing membrane laminate according to claim 1 or claim 2 wherein said first and second polymeric layers (16,18) of said carrier sheet (12) are cross-laminated with respect to each other. A waterproofing membrane laminate according to any one of claims 1 to 3 wherein said oil-resistant polymeric layer (20) comprises a polyvinyl acetate, a polyvinylidene chloride, a polyethylene terephthalate, or a polyamide. A waterproofing membrane laminate according to any preceding claim wherein said light-reflecting additive incorporated into said first carrier sheet polymeric layer (16) comprises titanium dioxide, calcium carbonate or zinc oxide. A waterproofing membrane laminate according to any preceding claim wherein said light absorbing additive of said second carrier sheet polymeric layer (18) comprises carbon black. A waterproofing membrane laminate according to any preceding claim wherein said oil-resistant polymeric layer (20) further comprises carbon black. A waterproofing membrane laminate according to any preceding claim wherein said oil-resistant polymeric layer (20) is located between said first and second carrier sheet layers (16,18). A waterproofing laminate according to any one of claims 1 to 7 wherein said second polymeric layer (18) is adhered to said first polymeric layer (16) and said oil-resistant polymeric layer (20) is located between said second polymeric layer (18) and said bituminous membrane layer (12). A waterproofing membrane laminate according to any one of claims 1 to 7 comprising at least two oil-resistant polymer film layers. A waterproofing membrane laminate according to any preceding claim wherein said first and second layers (16,18) of said carrier support sheet structure are oriented with respect to each other. A method for fabricating a rollable waterproofing membrane laminate (10) comprising the steps of: providing a carrier support sheet structure (14) by providing a first outer polymeric layer (16) incorporating an additive operative to reflect light; laminating said first polymeric layer to a second polymeric layer (18) which is thereby co-extensive with said first layer and which comprises a light absorbing additive; and providing at least one oil-resistant and oil-impermeable synthetic polymer film layer (20) by co-extruding a said oil-resistant and oil-permeable polymeric film layer (20) with at least one of said first and second carrier support sheet layers (16,18); and providing a waterproof and Waterproofing bituminous layer (12) whereby said bituminous layer (12) is non-removably attached to said carrier support sheet assembly (14) on a side opposite said first polymeric layer (16). The method of claim 12 wherein the step of providing the carrier support member includes the step of co-extruding together said second polymeric layer (18) and the or a said oil-resistant polymer film layer (20). The method of claim 12 or claim 13 comprising: (a) co-extruding together said first polymeric layer (16) with a first oil-resistant polymer film layer (20); (b) co-extruding together said second polymeric layer (18) with a second oil-resistant polymer film layer (20); (c) laminating said co-extruded sheets of (a) and (b) together; and (d) attaching said bituminous layer (12).

Inventors: JENKINS ROBERT FRANCIS, WIERCINSKI ROBERT ALAN, JENKINS, ROBERT FRANCIS, WIERCINSKI, ROBERT ALAN
Applicants: GRACE W R & CO, W.R. GRACE & CO.-CONN.
Application year: 1995
Main classification: B32B11
IPC codes: B29C47, B32B27, C08L95, B32B11, E04D5, B32B25, C09J7