Abstract:
An exterior finishing system including a bond-compatible composite membrane comprising a first self-adhesive material layer and a second rough fabric layer, and its use as an intermediate layer between a building structure substrate and exterior finishing materials is provided. Unlike conventional composite membranes, the bond-compatible composite membrane has a rough surface that allows bonding materials to adhere to it. Therefore, mechanical devices are not needed to attach the exterior finishing materials to the building structure.

Description:
CROSS REFERENCED TO RELATED APPLICATIONS  
       [0001]    The present application is a divisional of U.S. Ser. No. 10/154,992, filed on May 24, 2002, which is a continuation of U.S. Ser. No. 09/372,701, filed on Aug. 11, 1999, now U.S. Pat. No. 6,395,401, both of which are incorporated herein by reference. 
     
    
     
       TECHNICAL FIELD  
         [0002]    The invention is directed to composite membranes and their use as flashing around window frames, door frames, structural joints and other highly exposed surfaces of building frames or like structures prior to the application of exterior finishing materials, and their use as intermediate layers in the application of exterior finishing materials to building structures.  
         BACKGROUND  
         [0003]    Composite membranes are commonly used in the construction industry for protecting and waterproofing the frame structure of building frames and roofs. The exposure of a building frame or roofs to environmental factors such as water and moisture can result in devastating damage to the structure. Therefore, it is important for the composite membrane to bond tightly with the structure so environmental factors, such as water and moisture, are not allowed to contact and ultimately harm the structure. Composite membranes are applied to substrates such as a roof, wood framing, steel framing and plywood sheathing, gypsum sheathing and cement board sheathing before any exterior finishing materials are mounted on the substrates. The membranes are formed of materials such as polyethylene and rubberized bitumen or asphalt. Although they adhere well to substrates, these membranes have slick surfaces that are not compatible with conventional bonding materials such as adhesives and base coats normally used to adhere exterior finishing materials such as weather barriers and insulation, to the substrate. As a result, the exterior finishing materials must be mounted onto the composite membrane with mechanical devices such as screws and nails. Although the mechanical devices may effectively secure the exterior finishing materials to the composite membrane as well as the substrate, the mechanical devices must penetrate and perforate the composite membrane creating potential weak points in the membrane where damaging water and moisture may enter. The lack of tight adhesion between the composite membrane and the exterior finishing materials reduces the stability and wind load capacity of the structure.  
         SUMMARY  
         [0004]    In light of the problems with conventional composite membranes commonly used in waterproofing systems, it is an object of the present invention to provide a composite membrane that has a rough surface that will bond with materials such as adhesives and base coats.  
           [0005]    It is another object of the present invention to provide a method of adhering exterior finishing materials to highly exposed exterior portions of a building structure by utilizing a composite membrane as an intermediate layer between the structure and exterior finishing materials without the use of mechanical devices such as nails and screws.  
           [0006]    It is another object of the invention to provide a composite membrane capable of forming a bond with a tensile strength sufficient to withstand design wind loads required of a specific project which may be in excess of 70 PSF.  
           [0007]    In accordance with these objectives, the present invention provides a composite membrane having a rough surface that is compatible with bonding materials. This bond-compatible composite membrane comprises a bituminous material layer and a polyester fabric layer. The bond compatible composite membrane is utilized in a method of waterproofing wood framing, metal framing, plywood, sheathing gypsum, cement board and other highly exposed exterior portions of a structure by adhering the bituminous material layer to the structure and bonding exterior finishing materials such as weather barrier, insulation, exterior cladding and exterior insulation and finishing systems (EIFS) to the polyester fabric layer. The adhesive strength of the bond formed between the polyester fabric layer and the exterior finishing materials is sufficient to hold the exterior finishing materials on the substrate without mechanical devices that will perforate the composite membrane. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    [0008]FIG. 1 is a partial cross sectional view of a bond-compatible composite membrane adhered to release paper;  
         [0009]    [0009]FIG. 2 is a cross sectional diagram of a bond-compatible composite membrane positioned between a substrate and a weather barrier;  
         [0010]    [0010]FIG. 3 is an illustration of the bond-compatible composite membrane mounted on highly exposed portions of a framed structure such as the door frame, window frame and exterior joints, prior to the application of a weather barrier or other exterior surfacing materials;  
         [0011]    [0011]FIG. 4 is a partial cross sectional diagram of a finished exterior wall depicting the bond-compatible composite membrane adhered to a substrate, insulation material adhered to the bond-compatible composite membrane and exterior cladding mounted over the insulation.  
     
    
     DETAILED DESCRIPTION  
       [0012]    Referring now to FIGS. 1 and 2, the invention relates to a bond-compatible composite membrane  12  comprising a bituminous material layer  14  and a polyester fabric layer  16 . The bituminous material layer  14  of the bond-compatible composite membrane  12  protects substrate  20  from damaging environmental factors such as moisture. Substrate  20  may be wood framing, metal framing, plywood sheeting, gypsum board, cement, or other structural materials. The polyester fabric layer  16  of the composite membrane  12  has a rough surface that is compatible with, i.e. forms a bond with, bonding materials  24 . The bonding materials are used to secure exterior finishing materials  26  to the composite membrane  12 . The dual function of the single bond-compatible composite membrane  12  allows it to act as both an effective protective layer and an excellent bonding surface for adhesives, base coats and other bonding materials  24 , thereby eliminating the need to secure the exterior finishing materials  26  to the substrate  20  with mechanical devices that weaken the protective properties of the bituminous material.  
         [0013]    The Bond-Compatible Composite Membrane  
         [0014]    Referring again to FIG. 1, the bond-compatible composite membrane  12  is manufactured as a membrane sheet  10 . The membrane sheet  10  comprises a bond-compatible composite membrane  12  and release paper  18 . The bond-compatible composite membrane  12  is formed of two layers, a bituminous material layer  14  and a polyester fabric layer  16 . Preferably, the bituminous material layer  14  comprises between approximately 90%-99% by total weight of the composite membrane  12 . The polyester fabric layer  16  comprises between approximately 1%-10% by weight of the composite membrane, but preferably 8% by total weight of the composite membrane  12 . In addition, the polyester  10  fabric layer  16  is preferably a non-woven, mesh fabric.  
         [0015]    The bituminous material layer  14  comprises rubberized asphalt or bitumen and optionally, a polymer such as styrene-butadiene, and calcium carbonate. Preferably, the bituminous material layer  14  comprises, between approximately 67%-74% bitumen, between approximately 0%-15% styrene-butadiene, and between approximately 0%-15% calcium carbonate, by total weight of the composite membrane  12 .  
         [0016]    The membrane sheet  10  is manufactured by a reverse roll coating process (not pictured). Bituminous material is heated to a temperature of approximately 260° F. The hot liquid bituminous material is then poured onto release paper  18  forming the bituminous material layer  14  of the composite membrane  12 . Non-woven polyester fabric is placed on the bituminous material layer  14 . The non-woven polyester fabric forms the polyester fabric layer  16  of the composite membrane  12 . The release paper  18 , bituminous material, and polyester fabric are rolled through rollers filled with cold water to press to the polyester fabric into the bituminous material and solidify the resulting composite membrane  12 .  
         [0017]    The bond-compatible composite membrane  12  is between approximately 35 and 45 mils thick, and preferably approximately 40 mils thick. The membrane sheet  10  is wound into rolls and distributed for use in conjunction the application of exterior finishing materials and systems.  
         [0018]    Method of Adhering Exterior Finishing Materials to a Bond-Compatible Composite Membrane  
         [0019]    Referring now to FIGS. 2, 3 and  4 , the composite membrane  12  serves as an intermediate layer in the application of exterior finishing materials  26  to substrates  20 . Exterior finishing materials  26  are securely adhered to the exterior of a structure through the following procedure. Substrate  20  is primed with a primer  22  that is compatible with bituminous materials. However, if the substrate  20  is steel framing or other non-porous materials, the primer  22  is not necessary. A membrane sheet  10  is then provided and the release paper  18  is removed to expose the bituminous material layer  14  of the composite membrane  12 . The bituminous material layer  14  is then adhered to the primer coated substrate  20  to form a tight protective bond.  
         [0020]    As depicted in FIG. 3, the composite membrane  12  is preferably applied around highly exposed exterior surfaces of building such as door frames, window frames and construction joints that are particularly susceptible to environmental damage.  
         [0021]    Following the application of the bituminous material layer  14  to the primer  22  (if used) that was applied to the substrate  20 , bonding material  24  is applied to the polyester fabric layer  16  of the composite membrane  12 . Acceptable bonding materials  24  are adhesives, base coats such as cementitious compositions and acrylic compositions, and other materials that form a bond.  
         [0022]    Exterior finishing materials  26  such as weather barriers, insulation, exterior cladding and exterior insulation and finishing systems (EIFS) are mounted on the polyester fabric layer  16  of the composite layer  12  with the bonding material  24  applied to the polyester fabric layer  16 . The quality of the bond is determined by the tensile strength of the bond. Higher tensile strengths indicate stronger bonds. Bonding materials  24  preferred for use in conjunction with the composite membrane  12  have tensile strengths of at least 7.5 psi at room temperature, 7.0 psi at 120° F., and 3.7 psi at 0° F.  
         [0023]    The preferred bonding materials  24  for use with the composite membrane  12  are NC II Base Coat, Standard Basecoat, Senerquick Adhesive and Alpha Dry Basecoat. The tensile strength of bonds formed between the composite membrane  12  and these preferred bonding materials  24  were measured. The results of these measurements are set forth in Table I below.  
                               TABLE I                       Average Tensile           Senerquick   Alpha       Strength in psi   NCII Base Coat   Standard Basecoat   Adhesive   Dry Basecoat                   @ Room   18.0-22.0   19.0-25.0   7.5-9.1   19.3-20.9       Temperature   (20.0 +/− 2.0)   (22.0 +/− 3.0)   (8.3 +/− 0.8)   (20.1 +/− 0.8)       (approximately       70° F.)       @ 120° F.   18.0-22.0   17.0-21.0   7.0-11.0   15.0-21.0           (20.0 +/− 2.0)   (19.0 +/− 2.0)   (9.0 +/− 2.0)   (18.0 +/− 3.0)       @ 0° F.   17.0-19.0   17.0-23.0   3.7-4.9   18.0-22.0           (18.0 +/− 1.0)   (20.0 +/− 3.0)   (4.3 +/− 0.6)   (20.0 +/− 2.0)                  
 
         [0024]    The composition of the preferred bonding materials is set forth in Table II below.  
                                                 Bonding Material   Weight % of Components                                NCII Base Coat   Kaolin    1.0-2.0%           Water    1.5-20.0%           Acrylic Polymer   10.0-15.0%           Crystalline Silica   55.0-65.0%           Feldspar    1.0-5.0%           Mica    1.0-5.0%       Standard Basecoat   Crystalline silica   45.0-70.0%           Acrylic Polymer    5.0-30.0%           Talc    0.0-15.0%           Water   Balance       Senerquick Adhesive   Acrylic Polymer   15.0-20.0%           Water   35.0-40.0%           Calcium Carbonate   40.0-45.0%       Alpha Dry Basecoat   Silica, crystalline quartz   40.0-55.0%           Portland Cement   35.0-45.0%           Calcium Carbonate    2.0-5.0%           Fly Ash    1.0-3.0%           Polymer   Balance                  
 
         [0025]    The tensile strength of the bond is also indicative of the wind load strength of the bond. Consequentially, the high tensile strength of the bonds between the polyester fabric layer  16  and the bonding material  24  translates into higher wind resistance.  
         [0026]    The tensile strength of adhesive bonds formed with the preferred bonding materials  24  listed above are sufficient to support several layers of exterior finishing materials  26 , or exterior finishing systems formed of multiple layers of materials such as insulation  28  and exterior cladding  30  as depicted in FIG. 4.  
         [0027]    Many changes and modifications may also be made to the invention without departing from the spirit thereof. The scope of the changes will become apparent from the appended claims.