Water-resistant mastic membrane

Details Water-resistant mastic membrane Water-resistant mastic membrane

1997-07-23

2001-05-22

Copenheaver, Blaine (Department: 1771)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C427S207100

Reexamination Certificate

active

06235136

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to reinforced, water-resistant membranes used in water-proofing applications, and more particularly, to reinforced mastic weather-proofing systems.
BACKGROUND OF THE INVENTION
Many outdoor surfacing applications have employed asphalt for its weather resistance and superior mechanical properties under heavy loads. Asphalt is a dark cementitious material composed predominantly of bitumens. Most asphalts are now produced from the refining of petroleum and are used primarily in paving and roofing applications. At normal service temperatures asphalt is viscoelastic; at higher temperatures, it becomes viscous.
The water resistance of asphalt layers is essential to its durability. Asphalts that have a low content of soluble salts show a low water absorption. When asphalt picks up water, it softens and blisters. Bacteria and fungi are also known to attack the very low molecular weight portion of bituminous materials. Exposed asphalt films have, additionally, been known to harden and crack when exposed to ultraviolet radiation.
Asphalt-mastics are known to include mineral fillers which are added to influence their flow properties and reduce costs. Mineral-filled films show proven resistance to flow at elevated temperatures, improved impact resistance and better flame-spread resistance. Fillers may also increase the water absorption of asphalt, and can include ground limestone, slate flowers, finely divided silica, trapped rocks, and mica. Opaque fillers offer protection from weathering, and asbestos filler, because of its fibrous structure can be added to improve toughness. Asbestos fibers have also been added to asphalt paving mixes to increase the resistance to movement under traffic, and in roofing materials, for fire-retardant purposes.
Numerous asphalt-based membranes have been produced for smaller surface-area applications, such as in the patching of roads and roofs. Such membranes can be non-reinforced, or lightly reinforced and are known to have pressure sensitive characteristics. One example of a commercial membrane product, Road Glass from Owens-Corning Fiberglass, provides a membrane capable of accepting an embedded reinforcement at the job site. The Road Glass system involves melting asphalt-based mastic onto the targeted surface, followed by the application of a fiberglass layer, and then, an additional layer of asphalt mastic is provided to produce a composite membrane.
SUMMARY OF THE INVENTION
Reinforced water-resistant membranes are provided by this invention which include a laminated substrate, including a mastic layer adhered to a carrier layer and containing a fiber-containing reinforcement layer disposed within the mastic layer for increasing its mechanical properties. The membrane is capable of being bonded to an underlying substrate by applying heat or pressure to bond the mastic layer to the substrate.
In a preferred embodiment of this invention, a membrane is provided which includes a rubberized asphalt mastic layer reinforced with an open-mesh, glass-fiber reinforcement. A fabric carrier layer is located beneath a first major surface of the mastic layer for enabling the complete filling of the glass-fiber reinforcement layer by the mastic material. This membrane can be provided in roll form and can be bonded either by heat or pressure to an underlying substrate. The membrane of this embodiment has extremely favorable mechanical properties due to the fiberglass reinforcement mesh, including a tensile strength of at least about 300 psi. This membrane can be applied without a tack coat and is relatively easy to install.


REFERENCES:
patent: 3967032 (1976-06-01), Plotz
patent: 4151025 (1979-04-01), Jacobs
patent: 4386981 (1983-06-01), Clapperton
patent: 4588458 (1986-05-01), Previsani
patent: 4599258 (1986-07-01), Hageman
patent: 5439540 (1985-08-01), Lippman et al.
patent: 5456785 (1995-10-01), Venable
Grace Masonry Products “The System Solution to Complete Moisture Protection in Masonry Walls,” W.P. Grace & Co. (1994).

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