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Title:
CONSTRUCTION LAMINATES
Document Type and Number:
WIPO Patent Application WO/2018/023147
Kind Code:
A1
Abstract:
The present disclosure relates to flexible sheet-like materials for use in construction. In one aspect, there is provided a flexible sheet-like laminate comprised of at least a layer of a water vapour proof material and at least a layer of an acoustic dampening material, in which the layers are bonded together. Such a flexible sheet-like laminate would do away with the need for a liquid membrane, meaning waterproofing and acoustic dampening could be installed far quicker and easier than previously possible. In one form, the flexible sheet-like laminate further comprises at least a layer of a reinforcing material.

Inventors:
SCARDIGNO, Philip Anthony (30 Park Avenue, Woodville North, South Australia 5012, AU)
Application Number:
AU2017/000157
Publication Date:
February 08, 2018
Filing Date:
July 31, 2017
Export Citation:
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Assignee:
AXIS INNOVATION PTY LTD (30 Park Avenue, Woodville North, South Australia 5012, AU)
International Classes:
B32B15/06; B32B7/12; B32B15/08; B32B23/08; B32B25/08; E04B1/82; E04C2/24; E04C2/26
Domestic Patent References:
WO2010148439A12010-12-29
WO2011047429A12011-04-28
Foreign References:
US20130129998A12013-05-23
GB2478962A2011-09-28
FR2824094A12002-10-31
US20110183096A12011-07-28
US5298694A1994-03-29
GB1478691A1977-07-06
ES2339418A12010-05-19
Attorney, Agent or Firm:
MADDERNS PATENT AND TRADE MARK ATTORNEYS (GPO Box 2752, Adelaide, South Australia 5001, AU)
Download PDF:
Claims:
CLAIMS

1. A flexible sheet-like laminate comprised of at least a layer of a water vapour proof material and at least a layer of an acoustic dampening material, in which the layers are bonded together.

2. The flexible sheet-like laminate of claim 1, further comprising multiple layers of the water vapour proof material.

3. The flexible sheet-like laminate as in either of the preceding claims, further comprising multiple layers of the acoustic dampening material.

4. The flexible sheet-like laminate as in any one of the preceding claims, wherein the layers of water vapour proof material and acoustic dampening are laid in an alternating arrangement.

5. The flexible sheet-like laminate as in any one of the preceding claims, further comprising at least a layer of a reinforcing material.

6. The flexible sheet-like laminate of claim 5, further comprising multiple layers of the reinforcing material.

7. A flexible sheet-like laminate comprised of at least a layer of a water vapour proof material , at least a layer of an acoustic dampening material, and at least a layer of a reinforcing material, in which the layers are bonded together.

8. The flexible sheet-like laminate as in any one of the preceding claims, wherein the or each layer of water vapour proof material comprises a sheet of plastic.

9. The flexible sheet-like laminate as in any one of the preceding claims, wherein the or each layer of water vapour proof material comprises a polyethylene film.

10. The flexible sheet-like laminate as in any one of claims 1 through 7, wherein the or each layer of water vapour proof material comprises a sheet of foil.

1 1. The flexible sheet-like laminate as in any one of the preceding claims, wherein the or each layer of acoustic dampening material comprises a sheet of elastomeric material.

12. The flexible sheet-like laminate as in any one of the preceding claims, wherein the or each layer of acoustic dampening material comprises a sheet of a rubber material.

13. The flexible sheet-like laminate as in any one of claims 1 through 1 1 , wherein the or each layer of acoustic dampening material comprises a sheet of a synthetic rubber material.

14. The flexible sheet-like laminate as in any one of claims 5 through 13, wherein the or each layer of reinforcing material comprises a geotextile sheet.

15. The flexible sheet-like laminate as in any one of claims 5 through 13, wherein the or each layer of reinforcing material comprises a polyester fabric.

16. The flexible sheet-like laminate as in any one of claims 5 through 13, wherein the or each layer of reinforcing material comprises a non-woven polypropylene.

17. The flexible sheet-like laminate as in any one of claims 5 through 13, wherein the or each layer of reinforcing material comprises a woven polypropylene.

18. The flexible sheet-like laminate as in any one of the preceding claims, wherein at least one of the layers is adapted to be bonded to the other layers.

19. The flexible sheet-like laminate of claim 18, wherein the or each layer is so adapted by way of comprising an adhesive portion.

20. The flexible sheet-like laminate as in either of claims 18 or 19, wherein the or each layer is so adapted by way of comprising a self-adhesive portion.

21. A flexible sheet-like laminate comprised of at least a layer of a water vapour proof material and at least a layer of a reinforcing material, in which the layers are bonded together.

Description:
CONSTRUCTION LAMINATES

PRIORITY DOCUMENTS

[0001 ] The present application claims priority from:

Australian Provisional Patent Application No. 2016903024 titled "CONSTRUCTION LAMINATES" and filed on 1 August 2016; and

Australian Provisional Patent Application No. 2017900064 titled "CONSTRUCTION LAMINATES" and filed on 11 January 2017; the content of each of which is hereby incorporated by reference in its entirety. TECHNICAL FIELD

[0002] The present disclosure relates to flexible sheet-like materials for use in construction. BACKGROUND

[0003 ] Anyone who has experienced apartment or unit living will know the sound of someone walking on the ceiling above them or playing loud music in the room next door. Wet areas such as bathrooms and kitchens, balconies and general suspended areas with timber or tiled floors are known to be particularly noisy.

[0004] Wet areas are defined as areas within a building that are supplied with water. They require special consideration in new homes and renovations because of the high level of moisture they are subjected to and the risk that poorly lined wet areas can have on other rooms.

[0005] One solution for achieving sound reduction in such areas is to lay an acoustic mat beneath the flooring material. Where waterproofing is also required, this is achieved by rolling or brushing a liquid membrane over the acoustic mat. This process is time consuming; it includes a typical recoat time in the order of up to two hours, and a drying time in the order of 16 to 24 hours before tiles can be overlaid.

[0006] It is against this background and the problems and difficulties associated therewith that the present invention has been developed. [0007] Certain objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.

SUMMARY

[0008] According to a first aspect, there is provided a flexible sheet-like laminate comprised of at least a layer of a water vapour proof material and at least a layer of an acoustic dampening material, in which the layers are bonded together.

[0009] In one form, the flexible sheet-like laminate comprises multiple layers of the water vapour proof material.

[0010] In one form, the flexible sheet-like laminate comprises multiple layers of the acoustic dampening material.

[001 1 ] In one form, the layers of water vapour proof material and acoustic dampening are laid in an alternating arrangement.

[0012] In one form, an adhesive bonds the layers together.

[0013 ] In one form, at least one of the layers is adapted to be bonded to the other layers.

[0014] In one form, the or each layer is so adapted by way of comprising an adhesive portion.

[0015] In one form, the or each layer is so adapted by way of comprising a self-adhesive portion.

[0016] In one form, the or each layer comprises a first side and a second side, at least one of which comprises a self-adhesive portion. In one form, both the first and second sides comprise a self-adhesive portion.

10017] In one form, at least one of the layers comprises an adhesive backing. [0018 ] In one form, at least one of the layers comprises a self-adhesive backing. [0019] In one form, the adhesive is a pressure-sensitive adhesive.

[0020] In one form, the adhesive is a structural adhesive. [0021 ] A structural adhesive forms a bond via processes such as evaporation of a solvent, a reaction with UV radiation, a chemical reaction, heating or cooling. A pressure adhesive forms a bond by the application of pressure.

[0022 ] In one form, the flexible sheet-like laminate comprises at least a layer of a reinforcing material.

[0023] In one form, at least one of the layers is adapted to fuse to the other layers.

[0024] In one form, the laminate further comprises a matrix in which the layers are embedded.

[0025] According to a further aspect, there is provided a flexible sheet- like laminate comprised of at least a layer of a water vapour proof material and at least a layer of a reinforcing material, in which the layers are bonded together.

[0026] In one form, the reinforcing material possesses at least some acoustic dampening properties.

[0027] In one form, the flexible sheet-like laminate comprises multiple layers of the water vapour proof material.

[0028 ] In one form, the flexible sheet-like laminate comprises multiple layers of the reinforcing material.

[0029] In one form, the layers of water vapour proof material and reinforcing material are laid in an alternating arrangement.

[0030] In one form, the laminate further comprises at least a layer of an acoustic dampening material.

[0031 ] In one form, the flexible sheet-like laminate comprises multiple layers of the acoustic dampening material.

[0032] According to a further aspect, there is provided a flexible sheet-like laminate comprised of at least a layer of an acoustic dampening material and at least a layer of a reinforcing material, in which the layers are bonded together.

[0033 ] In one form, the layers of acoustic dampening material and reinforcing material are laid in an alternating arrangement.

[0034 ] In one form, the laminate further comprises at least a layer of a water vapour proof material. [0035 ] According to a further aspect, there is provided a flexible sheet-like laminate comprised of at least a layer of a water vapour proof material , at least a layer of an acoustic dampening material, and at least a layer of a reinforcing material, in which the layers are bonded together.

[0036] In one form, the or each layer of water vapour proof material comprises a sheet of plastic.

[0037] In one form, the or each layer of water vapour proof material comprises a P VC sheet or foil.

[0038] In one form, the or each layer of water vapour proof material comprises a polyethylene film.

[0039] In one form, the or each layer of water vapour proof material comprises a sheet of foil. In one form, the foil is an aluminium foil.

[0040] In one form, the or each layer of reinforcing material comprises a geotextile sheet.

[0041 ] In one form, the or each layer of reinforcing material comprises a polyester fabric.

Advantageously, polyester fabric can possess a fleece which is useful as a facing material (on either one or both sides) for the laminate because of its good mechanical adhesion.

[0042 ] In one form, the or each layer of reinforcing material comprises a non-woven polypropylene.

[0043] In one form, the or each layer of reinforcing material comprises a woven polypropylene.

[0044] In one form, the or each layer of acoustic dampening material comprises a sheet of elastomeric material.

[0045] In one form, the or each layer of acoustic dampening material comprises a sheet of a rubber material.

[0046] In one form, the or each layer of acoustic dampening material comprises a sheet of a synthetic rubber material.

[0047] In one form, the or each layer of acoustic dampening material comprises any one or more of felt, foam, polyester, and polypropylene blend materials.

[0048 ] In one form, the or each layer of acoustic dampening material comprises a sheet of chopped rubber strand. [0049] According to a further aspect, there is provided a method of manufacturing the above described flexible sheet-like laminate, the method comprising the step of feeding the layers between at last a pair of compression rollers.

[0050] In one form, the method further comprises heating at least one of the rollers to fuse the layers together.

[0051 ] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate by way of example the principles of the invention. While the invention is described in connection with such embodiments, it should be understood that the invention is not limited to any embodiment. On the contrary, the scope of the invention is limited only by the appended claims and the invention encompasses numerous alternatives, modifications, and equivalents. For the purpose of example, numerous specific details are set forth in the following description in order to provide a thorough understanding of the present invention.

[0052] The present invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the present invention is not unnecessarily obscured.

BRIEF DESCRIPTION OF DRAWINGS

[0053 ] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein:

[0054] Figure 1 is a schematic of an arrangement for forming a flexible sheet-like laminate according to a first embodiment;

[0055] Figure 2 is a schematic of an arrangement for forming a flexible sheet-like laminate according to a second embodiment.

[0056] In the following description, like reference characters designate like or corresponding parts throughout the figures.

DESCRIPTION OF EMBODIMENTS

[0057] Referring now to Figure 1, where there is illustrated a schematic of an arrangement for forming a flexible sheet-like laminate 40 according to a first embodiment, although it should be understood that the laminate 40 could be manufactured using other arrangements or methods. This particular arrangement comprises a pair of heated (optional) compression rollers H (although multiple pairs may be required), into which there is fed at least a first layer sheet 10, and a second layer sheet 20, and from which there is emitted the flexible sheet-like laminate 40.

[0058] The first and second layers 10 and 20 are compressed and bonded by fusing together between the rollers H, to form the flexible sheet-like laminate 40.

[0059] In this embodiment, the first layer sheet 10 comprises a water vapour proof material, and the second layer sheet 20 an acoustic dampening material. Preferably, but not essentially, the acoustic dampening material is one which will dampen both high and low frequency noise.

[0060 ] In this case, the water vapour proof material 10 comprises a sheet of plastic material, such as polypropylene, and the acoustic dampening material 20 comprises a sheet of rubber matting, where these have been fused together by the heat and pressure of the heated compression rollers H.

[0061 ] The above described flexible sheet-like laminate 40 does away with the need for a liquid membrane, meaning waterproofing and acoustic dampening could be installed far quicker and easier than previously possible.

[0062] In an alternate embodiment, the second layer sheet 20 comprises a reinforcing material, such as a geotextile sheet, which has been fused to the sheet of plastic material 10.

[0063] The geotextile sheet 20 provides mechanical strength, impact resistance, puncture resistance, rot resistance, and provides a surface which is well suited for the laying of tiles thereto.

10064] Referring now to Figure 2, where there is illustrated a schematic of an arrangement for forming a flexible sheet-like laminate 40 according to a second embodiment. As before, the arrangement comprises one or more pairs of heated compression rollers H, into which there is fed at least a first layer 10, a second layer 20, and a third later 30, and from which there is emitted the flexible sheet-like laminate 40.

[0065] The first, second and third layers 10, 20 and 30 are compressed and bonded together between the rollers H, to fonn the flexible sheet-like laminate 40.

[0066] In this embodiment, the first layer sheet 10 comprises an acoustic dampening material, the second layer sheet 20 comprises a water vapour proof material, and the third layer sheet 30 comprises a reinforcing material.

[0067] In this case, the water vapour proof material 20 comprises the polypropylene sheet, and the acoustic dampening material 10 comprises the sheet of rubber matting, and the reinforcing layer comprises 30 the geotextile sheet, where these have been fused together by the heat and pressure of the heated compression rollers H.

[0068] This flexible sheet-like laminate 40 offers all of the advantages of the above described embodiments, in that it is strong, waterproof and noise absorbing.

[0069] In a further non-illustrated embodiment, at least one of the layers comprises a self-adhesive backing for bonding the layers together without need for a primer, to form the flexible sheet-like laminate. This self-adhesive portion may be covered with either of a suitable, known pressure-sensitive or structural adhesive. In the case of a pressure-sensitive adhesive, heating may not be required to effect a bond between the layers. Moreover, where this layer with self-adhesive backing is to be sandwiched between layers of the second kind, both sides of this first layer will comprise self-adhesive portions.

[0070] The flexible sheet-like laminates described herein could have numerous applications in general construction, with uses including, but not limited to, internal wet areas, wet floors, showers, laundries, external wet areas, podiums, terraces, balconies, decks, roofs, suspended external floors and box gutters, roof gardens, earth shelters, planter boxes and retaining walls, suspended pool floors, spas, water features and fish ponds, potable water storage facilities, retention and water tanks.

[0071 ] Advantageously, laminates described herein can be applied to substrates including, but not limited to, render, screeds and general masonry surface, concrete blocks and clay brick, CFC, cement sheet, plasterboard surfaces, plasters and general mineral surfaces, aerated concrete panels and blocks, and metals.

[0072] Moreover, laminates described herein can form a fast and highly durable waterproof and vapour barrier, to which surface finishes such as tiles, screeds and toppings can be applied immediately after, or at least on the same day as, the laminate has been installed, avoiding delayed drying times. This significantly reduces labour and application times when compared to traditional waterproofing sheet and liquid systems.

[0073] The reinforcing material make the laminates described herein durable, tear and perforation resistant. Moreover, the reinforced laminate can resist surface cracks and provide an anti-fracture system on a floor.

[0074] When combined with the layer of a water vapour proof material, the acoustic dampening material makes the laminate a sound impact underlay which is simultaneously installed as part of the

waterproofing application. In use, the acoustic dampening material reduces the transfer of impact sound caused from general footfall. [0075] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[0076 ] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[0077] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substi tutions without departing from the scope of the invention as set forth and defined by the following claims.