LAWRENCE YONG, Joon Leong (Manufacturing Sdn BhdLot 56 & 57, Jalan Industri 2/2,,Taman Industri Integrasi Rawang,,Rawan, Selangor Darul Ehsan ., 48000, MY)
SANDRASEGARAN, S. Prema (Manufacturing Sdn BhdLot 56 & 57, Jalan Industri 2/2,,Taman Industri Integrasi Rawang,,Rawan, Selangor Darul Ehsan ., 48000, MY)
LAWRENCE YONG, Joon Leong (Manufacturing Sdn BhdLot 56 & 57, Jalan Industri 2/2,,Taman Industri Integrasi Rawang,,Rawan, Selangor Darul Ehsan ., 48000, MY)
| Claims "n 1] A method of rendering multi-layer lamination, for use as waterproof roof underlay, with nail-hole sealing property including the steps of: extruding an ethylene-methyl acrylate thermoplastic resin to form a copolymer layer; and incorporating at least one said copolymer layer as a bonding layer (1) in said multi-layer waterproof lamination. "n 2] A method of rendering multi-layer waterproof lamination roof underlay with nail-hole sealing property as in Claim 1 in which the method further includes a step of incorporating fiberglass with said copolymer layer. "n 3] A method of rendering multi-layer waterproof lamination roof underlay with nail-hole sealing property as in Claim 1 in which the method further includes a step of incorporating lino-fabric material with said copolymer layer. "n 4] A multi-layer lamination including at least one bonding layer (1) for use as waterproof roof underlay is characterized in which said bonding layer (1) is a copolymer layer extruded from an ethylene- methyl acrylate thermoplastic resin, whereby said waterproof lamination exhibits a nail-hole sealing property. "n 5] A multi-layer waterproof lamination roof underlay as in Claim 4 in which there are five layers in the waterproof lamination. "n 6] A five-layer waterproof lamination roof underlay as in Claim 5 in which the five layers comprises: a topmost layer made from metallic material (5); an intermediate second bonding layer (1); a middle third layer made from film (4) or woven fabric material (3); an intermediate fourth bonding layer (1); and a bottommost layer made from non- woven material (2); wherein either or both bonding layers (1) are extruded from an ethylene-methyl acrylate thermoplastic resin, whereby said waterproof lamination exhibits a nail-hole sealing property. "n 7] A five-layer waterproof lamination roof underlay as in Claim 5 in which the five layers comprises: a topmost layer made from non- woven material (2); an intermediate second bonding layer (1); a middle third layer made from film (4) or woven fabric material (3); an intermediate fourth bonding layer (1); and a bottommost layer made from non- woven material (2); wherein either or both bonding layers (1) are extruded from an ethylene-methyl acrylate thermoplastic resin; whereby said waterproof lamination exhibits a nail-hole sealing property, "n 8] A five-layer waterproof lamination roof underlay as in Claim 6 or 7 in which the non- woven material (2) can be selectively colored, "n 9] A five-layer waterproof lamination roof underlay as in Claim 6 or 7 in which the bonding layer (Ib) is incorporated with fiberglass, "n 10] A five-layer waterproof lamination roof underlay as in Claim 6 or 7 in which the bonding layer (Ia) is incorporated with lino-fabric material. |
Title of Invention: WATERPROOF LAMINATION ROOF UNDERLAY WITH NAIL-HOLE SEALING PROPERTY
Technical Field
The present invention relates generally to a waterproof lamination roof underlay material. It relates specifically to a multi-layer waterproof lamination roof underlay with nail-hole sealing property. Background Art
Roofs and like building surfaces exposed to the weather must be provided with a continuous layer impermeable to water, a so-called 'waterproof membrane'. For many years (and still today), the most common 'membrane' comprises several plies of substrates bonded or glued together with hot or cold-applied asphalt, tar, polyolefine and so on. The bonding of the several plies together is usually accomplished in situ upon the roof, hence the terminology 'built-up waterproof membrane'.
Bitumen is a general term for petroliferous substances ranging from true petroleum through the so-called mineral tars to asphalt. Currently bituminous product is widely used as the roof underlay. Bitumen is heavy. At high temperature, it becomes viscous and at low temperature, it may crack. Roof underlay is normally nailed on wooden batten. After some time, rain water leaks through nail holes. With leakage, wooden batten may rot over time. This rain water leakage problem had been with the roofing industry for a long time. As a counter-measure, after insulation is nailed to battens, a foil tape is currently used to seal on the nail to avoid any possible leakage.
Past efforts were focused on the multi-layer composition of underlay material as barrier layer for moisture and water. A prior art roof of a structure comprises a roofing surface having an eave, an underlay bonded to said roofing surface and a roofing material bonded to said underlay. Hence, multi-layer roofing laminates are commonly used to tackle the waterproof problem.
For an example, in United States Patent No. 5434009, an acrylic based composition/ asphaltic roofing laminate is disclosed. The new roofing composition provides for an application of an acrylic polymer to a hot or cold asphaltic layer. The acrylic polymer is provided with barrier characteristics that resist the movement of mobile phases into the shield layer. The barrier characteristics are provided by ensuring that the polymer include a minor (preferably less than 5%) amount of metal complexes. The polymer should be present in an amount sufficient to ensure that it can form a continuous film on application to the base asphaltic layer. Pigment volume concentration should not be present in an amount that would interfere with the barrier characteristics, with the pigment volume concentration being less than 35%.
For another example, in United States Patent No. 4600635, pressure sensitive bitumen-based adhesive compositions are provided which comprise bitumen, oil, an ionomeric elastomer, and gilsonite. The adhesives are particularly useful as self- adherent waterproofing layers in roofing. The presence of gilsonite can result in substantial increases in the shear strength of these adhesives at the relatively high temperatures encountered in roofing applications.
Yet, for another example in United States Patent No. 5142837, a laminated roofing material includes an aluminium foil top sheet laminated to a polyethylene film by an ionomer resin. After the sheets are bonded together, they are cooled to set the resin and an asphalt coating is applied to the exposed polyethylene sheet and covered with a release paper. The roofing material is applied over an underlayment to form a roof supported by conventional sheeting material.
Nevertheless, there has been little attention being paid to nail holes left on bituminous underlay. There has been practically no previous patent in overcoming this problem. Prior art puncture sealing composition is available for a tubeless tyre. United States Patent No. 3981342 taught a composition comprising a major proportion of low molecular weight liquid elastomer, a minor proportion of a high molecular weight elastomer and a cross-linking agent in an amount sufficient to give a partial cure. An example is a blend of 60 parts of depolymerized natural rubber and 40 parts of cis- polyisoprene, partially cross-linked by the action of 6 parts of tetra-m-titanate so as to provide a gel content of about 40%. This prior art composition is clearly unsuitable for use in a waterproof roof underlay material. Summary of the Invention
One primary object of the present invention is to search and identify a material for use in waterproof lamination with a nail-hole sealing property, suitable for use as a roof underlay material.
A second object of the present invention is that the waterproof lamination roof underlay material should be light weight and temperature stable.
A third object of the present invention is that a multi-layer waterproof lamination roof underlay is formed with at least a bonding layer, made from said material with nail-hole sealing property, and various substrates.
These objects are achieved in that a special bonding layer is extruded from an ethylene-methyl acrylate thermoplastic resin and used in a multi-layer waterproof lamination roof underlay. This special bonding layer is also called the copolymer layer. For added properties, fiberglass or lino-fabric material can be incorporated.
Other objects and advantages of the present invention will become evident following the disclosure below. Brief Description of the Drawings
In order that the present invention may be more readily understood, the following description is given, by way of examples, of five combinations of a five-layer waterproof lamination roof underlay made in accordance with the present invention.
Reference will be made to the accompanying drawings, in which:
Figure Ia shows a first combination of a five-layer waterproof lamination roof underlay in accordance with the present invention.
Figure Ib shows a second combination of a five-layer waterproof lamination roof underlay in accordance with the present invention.
Figure Ic shows a third combination of a five-layer waterproof lamination roof underlay in accordance with the present invention.
Figure 2a shows a fourth combination of a five-layer waterproof lamination roof underlay in accordance with the present invention.
Figure 2b shows a fifth combination of a five-layer waterproof lamination roof underlay in accordance with the present invention. Disclosure of Invention Detailed Description
For ease of explanation, same numerals are used to denote same material. Where there is a need to differentiate same material, suffices 'a' and 'b' are added.
The Inventors had identified a copolymer composition of ethylene-methyl acrylate thermoplastic resin with improved properties. It gives improved impact strength, flowability and thermal stability. The main disadvantage of this discovery is that the cost of this ethylene-methyl acrylate thermoplastic resin is high.
The Inventors next experimented with this copolymer composition in waterproof lamination roof underlay application and discovered a nail-hole sealing property, which was not previously known. In other words, after nail holes are pierced through the roof underlay material, these nail holes are automatically closed off or sealed. Center of Construction Material had issued a Japanese Architectural Standard Specification on 'test of the waterproof at nail holes'. The Inventors had conducted a comparison study of waterproof lamination roof underlays made from bitumen and said copolymer composition.
As a furtherance of the above experimentation, a copolymer layer is extruded from said ethylene-methyl acrylate thermoplastic resin. Other materials like fiberglass or lino-fabric material can be incorporated to form variants of this copolymer layer. Fiberglass or lino-fabric material is incorporated to provide strength and better appearance. At least one copolymer layer or its variant can be incorporated into a multilayer waterproof lamination roof underlay which is disposed underneath a roof deck when in use.
According to current multi-layer waterproof lamination roof underlay practice, substrates made from woven and non- woven material, aluminium or other metallic films can be suitably applied to one or more said copolymer layer. These substrates provide mechanical strength and variation in appearance.
A five-layer waterproof lamination roof underlay is preferred in accordance to the teaching of the present invention. The topmost layer faces the underside of the roof deck.
Essentially, a normal five-layer waterproof lamination roof underlay comprises: a topmost layer made from non- woven material (2); an intermediate second bonding layer (1) made from either polymer or copolymer material; a middle third layer made from film (4) or woven fabric material (3); an intermediate fourth bonding layer (1) made from either polymer or copolymer material; and a bottommost layer made from non- woven material (2).
Essentially, a radiant five-layer waterproof lamination roof underlay comprises: a topmost layer made from metallic material, particularly aluminium (5); an intermediate second bonding layer (1) made from either polymer or copolymer material; a middle third layer made from film (4) or woven fabric material (3); an intermediate fourth bonding layer (1) made from either polymer or copolymer material; and a bottommost layer made from non- woven material (2).
The metallic material, particularly aluminium (5), is used as a radiant layer to reflect heat from the sun.
Where the topmost and bottommost layers are made from non- woven material (2), the non- woven material (2) can be colored by adding color pigments of black, grey, green or other colors.
The bonding layer (1) is made from either polymer or copolymer material. Polymer refers to polyethylene (PE). Copolymer refers to an ethylene-methyl acrylate thermoplastic resin. The copolymer has a nail-hole sealing property. Fiberglass or lino- fabric material can be incorporated into said thermoplastic resin composition according to the present invention to form variants of the copolymer layer.
It is important to note that there can be various combinations in the above five-layer compositions.
Figures Ia to Ic show three combinations of a normal five-layer waterproof lamination roof underlay according to the present invention.
In a first combination as shown in Figure Ia, a normal five-layer waterproof lamination roof underlay according to the present invention comprises in order: a topmost layer made from non- woven material (2); an intermediate second bonding layer (1); a middle third layer made from woven fabric material (3); an intermediate fourth bonding layer (1); and a bottommost layer made from non-woven material (2).
In a second combination as shown in Figure Ib, a normal five-layer waterproof lamination roof underlay according to the present invention comprises in order: a topmost layer made from non- woven material (2); an intermediate second bonding layer (1); a middle third layer made from film (4); an intermediate fourth bonding layer (1); and a bottommost layer made from non- woven material (2).
In a third combination as shown in Figure Ic, a normal five-layer waterproof lamination roof underlay according to the present invention comprises in order: a topmost layer made from non- woven material (2); an intermediate second bonding layer (1); a middle third layer made from film (4); an intermediate fourth bonding layer (Ia) incorporated with lino-fabric material; and a bottommost layer made from non- woven material (2).
Figures 2a and 2b show two combinations of a radiant five-layer waterproof lamination roof underlay according to the present invention, where the topmost layer is a metallic layer.
In a fourth combination as shown in Figure 2a, a radiant five-layer waterproof lamination roof underlay according to the present invention comprises in order: a topmost layer made from aluminium material (5); an intermediate second bonding layer (1); a middle third layer made from film (4); an intermediate fourth bonding layer (1); and a bottommost layer made from non- woven material (2).
In a fifth combination as shown in Figure 2b, a radiant five-layer waterproof lamination roof underlay according to the present invention comprises in order: a topmost layer made from aluminium material (5); an intermediate second bonding layer (Ib) incorporated with fiberglass; a middle third layer made from film (4); an intermediate fourth bonding layer (1); and a bottommost layer made from non- woven material (2).
To those skilled in the art, there may be other combinations of five-layer composition and other multi-layer compositions that fall within the scope of the present invention.
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