Patent Publication Number: US-2005118446-A1

Title: Waterproofing air and vapor barrier membrane

Description:
TECHNICAL FIELD  
      The present invention relates to an integrated waterproofing air/vapor barrier membrane that does not require removal of a release sheet liner before application on a surface to be protected from weather conditions. More particularly, the waterproofing air/vapor barrier membrane of the present invention integrates a permeable sheet liner allowing passage of a contiguous impervious composition.  
     BACKGROUND ART  
      Many related art water devices exist for covering or protecting surfaces from water penetration. These include waterproof coverings different surfaces and coatings. Similarly there are numerous protective courses which are applied over the waterproof surface to protect it  
      On the other hand, it is known that bitumen-based membranes are used for waterproofing in construction. Such membranes normally feature a reinforcement made of non-woven polyester cloth or of a layer of reinforced glass such as fiberglass. One of the membrane surfaces is coated with small slate flakes of various colors, similar to granules, for protection against ultraviolet rays.  
      The users of these types of membranes currently face serious problems when trying to seal together contiguous membranes because of the relatively complex steps that must be carried out to connect the two contiguous or adjacent ends. Of course, if an effective seal is not attained, the membrane system will leak and not achieve its very purpose.  
      Most of membranes known in the art for sealing a structure or a surface need the release of one part, such as a non-adherent sheet on one face of a impervious layer before application on the surface.  
      Waterproofing barrier membranes are generally obtained in sheets of 3, 4 or 5 mm thickness and, if total or partial adhesion to the support is required, they can be applied either by means of a propane-gas torch, which by liquefying the bituminous mass makes it adherent to the support, or by using hot air-blown bitumen which acts as an adhesive.  
      However, while membranes based on bitumen modified with styrene-butanediene-styrene (SBS) as known in the art, yield good results with both methods (with preference for the air-blown bitumen method, due to some limitations of the SBS membrane with the torch method, such as excessive softening which almost always prevents rapid and easy application of the membrane, especially in summer), it is recognized that polyolefin-based membranes generally yield the best results only with the flame method; this especially because otherwise, in the course of time, adhesion tends to decrease due to the forming of an oily layer between the air-blown bitumen and the membrane which causes its separation in the course of time.  
      On another aspect in building construction requirements, air leakage can account for an important part of the total heat loss in home because warm air leaks out while cold air leaks in. Along with the air, moisture (vapor) escapes and can condense inside the walls or attic that could cause serious structural damage when mold, mildew and rot occurs. A good seal ensures less air infiltration as well as drier insulation and building interior.  
      To avoid air and vapor transfers, new-building manufacturers use state of the art products to create an air/vapor barrier envelope. The most important property of an air-vapor barrier is the ability to resist airflow and air pressure. A continuous air/vapor barrier completely encloses air within a building, keeping moisture from entering insulated cavities where it can condense into water. At the opposite, a vapor retarder inhibits vapor diffusion, but remains partially permeable to air and humidity.  
      Bitumen-based layers are often applied to masonry or sheathing material to create an air barrier system. These membranes are relatively impermeable to water, and thus constitute vapor barriers.  
      The problems of hardening the handling during application of waterproofing barrier membranes because of the release of paper or because of the use of a torch demonstrate that there is still an important need in the art for new waterproofing and air/vapor barrier membranes.  
     SUMMARY OF THE INVENTION  
      One object of the present invention is to provide an integrated waterproofing membrane comprising a waterproofing material layer capable to transude through a sheet of fibers or a sheet of paper, having opposite first and second sides, the first side being coated with a non transudent impervious surfacing material which is adherent to the waterproofing material and the second side being coated with an adherent support sheet composed of material allowing passage of the waterproofing material through the adherent support sheet to enter in contact with a surface on which the integrated waterproofing membrane is applied, the adherent support sheet being capable also of allowing passage there through of an adhesive material previously applied thereon or on a surface on which the integrated waterproofing membrane is to be applied.  
      The waterproofing material layer may be composed of transuding material selected from the group consisting of bitumen, a polymer, and a resin, wherein the bitumen can be polymer-modified asphalt.  
      The thickness waterproofing material layer may be between 0.1 to 8 mm.  
      In accordance with the present invention there is provided an waterproofing membrane in which an impervious surfacing material is composed a non transudent material that may be selected from the group consisting of a polymer, a resin, a plastic, a metal, a polyester, a polypropylene, a polybutyrene, a polyimide, a polycarbonate, a polyamide, a polyethylene, a polystyrene, a polyvinylchloride, a fluoroplastic, a sulfone polymer, and a polyvinylidene chloride. Also, the support sheet may be composed of paper, fabric, fiber network, or mixture thereof.  
      The waterproofing material may further comprise up to 50% by weight of filler.  
      The waterproofing material may comprise between 50 to 100% of bitumen, and up to 50% by weight of at least one copolymer. The mixture of the bitumen and a copolymer generally forms 100% of the waterproofing material. The copolymer can be composed of ethylene, propylene, butene, derivative or mixture thereof.  
      Another object of the present invention is to provide a paneling material covered, at least partially, with the air/vapor barrier membrane of the present invention.  
      In accordance with the present invention, there is provided a barrier membrane substantially impervious to atmospheric air and vapor for covering a construction surface or an area comprising a sealing material layer having opposite first and second sides, the first and second sides being coated with a support sheet composed of material allowing transudation or fusion of the sealing material through the support sheet to allow self-adhesion of the first side of the barrier membrane on the construction surface, and to a second surface on the second side.  
      The sealing material can be composed of air- and water-repellant material selected from the group consisting of bitumen, a polymer, a resin, and a mixture thereof, where the bitumen can be a polymer-modified asphalt.  
      The sealing material may further comprises up to 40% by weight of filler.  
      The support sheet can be composed of material selected from the group consisting of a polymer, a resin, a plastic, polyester, a polypropylene, a polybutyrene, a polyimide, a polycarbonate, a polyamide, a polyethylene, polystyrene, a polyvinylchloride, a fluoroplastic, a sulfone polymer, and a polyvinylidene chloride.  
      The sealing material may comprise between 50 to 100% of bitumen, and up to 50% by weight of at least one copolymer, wherein combination of the bitumen and the copolymer forms 100% of said sealing material. The copolymer can be styrene-butanediene-styrene, ethylene, propylene, butene, a derivative or a mixture thereof.  
      The sealing material is capable to transude or fuse through support sheet on at least one side after heating of the barrier membrane.  
      Another object of the present invention is to provide a laminated panel used for construction and covered at least partially with an integrated and air/vapor barrier membrane as described herein. The laminated panel can be a board of wood, concrete, gypsum, perlite, kraft, foam, wood fiber or plywood.  
      Another object of the present invention is to provide a method for protecting a construction surface against atmospheric air and vapor comprising: 
          a) applying a construction surface with a waterproofing and air/vapor barrier membrane as defined herein; and     b) heating the barrier membrane applied on the construction surface for a time and to a temperature allowing the sealing material to transude or fuse through one side of the support sheet and adhere to the construction surface.        

      A structural panel can additionally adhered to the second side of the barrier membrane before or after adhesion to a construction surface.  
      The structural panel can be a board of insulating material, a paper sheet, or a metallic sheet.  
      For the purpose of the present invention the following terms are defined below.  
      The term “bitumen” as used herein is intended to mean residue from atmospheric distillation of crude oil or of a mixture thereof with a slightly oxidized product. The softening point of the various types varies from 36° C. to 140° C., and the penetration number is generally comprised between 40 to 350 dmm; bitumen which have a penetration number comprised between 60 to 220 dmm and a softening point comprised between 60° C. and 120° C. are preferably used for modification with polymers. It is furthermore possible to use mixture of various types of bitumen, and the properties of the bitumen can be modified by adding mineral oils, fatty substances, chemical agents which make it impenetrable to roots, and others.  
      The term “copolymer” as used herein is intended to mean an elastic polymer which may be formed with ethylene, polyester, polypropylene, polybutyrene, polyimide, polycarbonate, polyamide, polyethylene, polystyrene, polyvinylchloride, fluoroplastics, sulfone polymers, polyvinylidene chloride, butene, derivatives or mixtures thereof. The ratios of polymers used in preparing a mixture may vary depending of the physical and chemical properties needed in a waterproofing or sealing material. For example, a waterproofing or sealing material according to the present invention may comprise between 5 to 15% by weight of copolymers. Also, for example, one type of mixture of copolymers, which can be used in the waterproofing or sealing material, may comprises between 25 to 70% propylene, 20 to 70% butene and 0 to 15% ethylene.  
      The terms “sealing” or “sealed” as used herein are intended to mean the capacity or property of a matter to significantly prevent the passage of a gas or a liquid through a material or a structure.  
      The terms “transudent” or “transuding” as used herein is intended to mean the capacity or property of a matter to transude, to exude, to excrete, to fuse, to transpire, to diffuse, or to pass through pores or interstices of a layer, as a sheet of paper for example. A matter capable to transude, slowly or rapidly, may be liquid, viscous, or pasty, and may have a physical state, meaning that the transuding matter may be more or less viscous for example, depending of the ambient temperature. The support sheets on both sides of the barrier membrane of the present invention can be either transuding of non-transuding. A non-transuding matter is relatively solid, and does not transude, exude, excrete, transpire, diffuse, or pass through pores or interstice. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
      Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:  
       FIG. 1  illustrates a cross-section view of an integral waterproofing membrane constructed in accordance with one embodiment of the present invention;  
       FIG. 2  illustrates according to one embodiment of the present invention a cross-section view of an integral waterproofing membrane adhered to a surface that is to be waterproofed;  
       FIG. 3  illustrates a cross-section view of a barrier membrane constructed in accordance with one embodiment of the present invention; and  
       FIG. 4  illustrates according to one embodiment of the present invention a cross-section view of a barrier membrane adhered to a surface that is to be sealed or protected against atmospheric air and/or vapor; and  
       FIG. 5  illustrates the barrier membrane of the instant invention adhered to a gypsum board on one side and to an insulating board on the other side. 
    
    
      It will be noted that throughout the appended drawings, like features are identified by like reference numerals.  
     DISCLOSURE OF THE INVENTION  
      As illustrated in  FIG. 1 , an integral waterproofing and air/vapor barrier membrane  10  constructed in accordance with one embodiment of the present invention includes a waterproofing or sealing material layer  12 , an impervious surfacing material  14  adhered to an integrated adherent support sheet  16 .  
      Referring to  FIG. 2 , the integral waterproofing or air/vapor barrier membrane  10  of the invention can be applied on a construction surface  18  which can be composed of concrete, wood or other matter to be waterproofed.  
      As illustrated in  FIG. 3 , an integral waterproofing and air/vapor barrier membrane  10  constructed in accordance with one embodiment of the present invention includes a waterproofing or sealing material layer  12 , and adherent support sheets  16  adhered to opposite sides of the waterproofing or sealing material layer  12 .  
      Referring to  FIG. 4 , the waterproofing and air/vapor barrier membrane  10  of the invention can be applied on a construction surface  18  which can be composed of concrete, wood or other matter to be sealed or protected against atmospheric air and/or vapor.  
      In  FIG. 5 , a waterproofing and air/vapor barrier vapor  10 , comprising according to the present invention waterproofing or sealing material  12  with adherent support sheets  16 , allows, in addition of preventing air or vapor infiltrations through a wall structure  11 , the fixation of an insulating matter  20  on a gypsum board  22  secured on uninsulated steel studs  24 .  
      In one embodiment of the present invention, there is provided a waterproofing and air/vapor barrier membrane comprising an adherent support sheet on one side of a waterproofing or sealing material layer, and porous in manner to allow the waterproofing or sealing material to pass through the integrated support sheet, and an impervious material on the other side of the waterproofing or sealing material layer.  
      One particular embodiment of the present invention is to provide an air/vapor barrier membrane in which is integrated a non-released adherent support sheet. Surprisingly, it has been observed that the use of such a support sheet which has not to be released during applying the barrier membrane on a surface to be sealed or protected, renders the integrated waterproof and air/vapor barrier membrane more resistant to stretching, easier to handle and apply, and allows for stability and efficiency of sealing to provide to a surface.  
      One particular embodiment of the present invention is to provide an integrated waterproofing membrane in which is integrated a non-released adherent support sheet. Surprisingly, it has been observed that the use of such a support sheet which has not to be. released during applying the waterproofing membrane on a surface to be waterproofed, renders the integrated waterproofing membrane more resistant to stretching, easier to handle and apply, and allows for stability and efficiency of waterproofing to provide to a surface.  
      In one particular embodiment of the present invention, under the action of warming, the sealing material of a membrane reaches a temperature above its softening point, transpires or transudes through the support sheet and fuses with the warmed sealing material of an adjacent piece, band or sheet of the barrier membrane, therefore creating an uninterrupted layer of sealing material on the surface on which it is adhered. Alternatively, the waterproof barrier membrane can be joined to an adjacent piece or band or sheet of barrier membrane of the instant invention with a tape applied concomitantly at the juncture of both membranes.  
      In one particular embodiment of the present invention, under the action of warming, the sealing material of a membrane reaches a temperature above its softening point, transpires or transudes through the support sheet and fuses with the warmed sealing material of an adjacent piece, band or sheet of the barrier membrane, therefore creating an uninterrupted layer of sealing material on the surface on which it is adhered. Alternatively, the barrier membrane can be joined to an adjacent piece or band or sheet of barrier membrane of the instant invention with a tape applied concomitantly at the juncture of both membranes.  
      The adherent support sheet may be composed of paper, such as Kraft paper, having a thickness of between 0.2 to 3 mm, and a density of between 20 to 60 pounds. Preferably the support is composed of paper having density of 36 to 44 pounds. Alternatively, the support sheet may be composed of different fabrics known in the art. The fabric can be composed cotton synthetic matter, polyester, nylon, or any other matter that can be processed in a fabric porous enough to allow passage a contiguous waterproofing material through it. The porosity of the support sheet may be calibrated or adjusted to allow transudation of a waterproofing material by one side it, and transudation of glue by the other side of it in manner that a contact between the waterproofing material and the glue is done inside the support sheet.  
      The resulting waterproofing and air/vapor barrier membrane may therefore be used to prepare rolled up jumbo rolls. The rolls that can be prepared with the waterproofing and air/vapor barrier membrane of the present invention can be of size, in length and width, superior to what it is possible to other membranes or methods known in the art.  
      The waterproofing and sealing material possesses a coating temperature at which it can be coated on an impervious or impermeable film, sheet or plaque as a viscous liquid. The waterproofing and sealing material may alternatively be coated, for example, when being below a flowing temperature of between about 80° C. to 115° C., on another film or support sheet which is permeable to the waterproofing and sealing material when the temperature of the waterproofing and sealing material is above its softening temperature, which may be for example of 100° C. The softening and flowing temperatures of the waterproofing and sealing material may vary depending on its composition.  
      The waterproofing and sealing material layer of the present invention is preferably composed of a polymer-modified bitumen such as a styrene-butanediene-styrene (SBS) block polymer, and can include one or more fillers such as limestone or the like to provide the desired consistency and physical properties for use in the integrated membrane. The types of filler commonly used in this type of mixture are various. Among them, it is possible to include slate powder, calcium carbonate, talc, kaolin and other compounds that are well known in the art. The purpose of the use of filler is to increase the stability of the mixture and reduce. Preferably, the filler used may have such a fineness as to pass through a 75-micron screen, although fillers which pass to an extent through a 60-micron (200-mesh) screen may also be used.  
      The present invention utilizes a wide variety of materials to form support sheet on one or both sides of the waterproofing and air/vapor barrier membrane of the present invention. Alternatively, the adherent support sheet formed, for example but without limiting it to, with an impervious material can be substantially impermeable to air, vapor and water and, based on the waterproofing and air/vapor barrier membrane&#39;s end use, capable of stretching with movement of the surface to which it is ultimately applied. The support sheet can be formed of natural rubber or of a synthetic organic polymer such as polyethylene, polyvinylchloride, fluoroplastics, sulfone polymers, polyvinylidene, polypropylene or other polyolefin, a polyamide, a polyester, for example a polyethylene terephthalate, a polyurethane, a polyvinyl halide, such as a polyvinyl chloride and copolymers thereof, such as a polyvinyl chloride and viriylidene chloride, a synthetic rubber, such as polychloroprene or butyl rubber, regenerated cellulose, cellulose, cellulose ethers or cellulose esters.  
      In one embodiment of the present invention, the porosity of the adherent support sheet can be calibrated or adjusted to allow transudation of a sealing material by one side of it, and transudation of glue by the other side of it in manner that a contact between the sealing material and the glue is done inside the support sheet.  
      Another embodiment of the present invention is to provide an integral waterproofing and air/vapor barrier membrane in which the support sheet can be a film in the form of a solid sheet, cellular film or woven and non-woven fabrics which are sufficiently non-porous to restrict the flow of the hot bituminous composition there through when applied.  
      The waterproofing and air/vapor barrier membrane of the present invention is used to make impervious structures or surfaces constructed of materials such as wood, metal, plastics, or concrete which can be air- and water-penetrable either inherently or as a result of imperfections such as cracks or pores. Rendering a surface or structure impervious as used herein means eliminating the ability of air, vapor and water to penetrate or pass through the surface or structure.  
      The integral waterproofing and air/vapor barrier membrane of the present invention may be considered also as a weather proofing membrane which is designed to be laminated to most common building sheathing material such as gypsum boards, perlite boards, wood fiber boards, insulating board or plywood.  
      According to another embodiment of the present invention, in addition of conferring a protection against atmospheric air, gas, vapor, humidity, or water, the barrier membrane confers the capability to act as an adhesive between two surfaces, allowing therefore the possibility of fixing a supplementary board on a surface already sealed or protected with a barrier membrane of the present invention. As for example, but without limiting it to, the barrier membrane can be applied on a surface as defined herein bellow, such as a concrete foundation, or a wall, against which a insulating panel or any insulation material is directly fixed on the other surface of the barrier membrane. This characteristic If the instant barrier membrane may avoid the use of nails, screws, glue or any other device for fixing such a material, the barrier membrane keeping its air and vapor barrier characteristic.  
      The barrier membrane of the present invention when used as a building envelope allows for providing a continuous air and vapor barrier to control air or vapor leakage into, or out of the sealed or protected space. The barrier membrane is also provided for interior partitions between sealed or protected space designed to maintain temperature or humidity levels which differ from those in the sealed or protected space by more than 50% of the difference between the sealed or protected space and design ambient conditions.  
      The barrier membrane of the present invention can be continuous, with all joints made air- and vapor-tight with or without glue, tape or any other additional method other than heating the joints.  
      The present barrier membrane is capable of withstanding positive and negative combined design wind, fan and stack pressure on the envelope without damage or displacement, and allow transfer of the load to the structure. The barrier membrane of the present invention is stable between adjacent structures or materials under different physical constraints.  
      In one embodiment of the present invention, there is provided a waterproofing and air/vapor barrier membrane that allows connection between different construction structures, such as between foundation and walls, walls and windows or doors, between different wall systems, wall and roof, wall and roof over sealed or protected space, wall, floors and roof across construction, control and expansion joints, and between walls, floors and roof to utility, pipe and duct penetrations.  
      The embodiment(s) of the invention described above is (are) intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.