Single-ply roofing membrane with laminated, skinned nonwoven

• US 6,502,360 B2
• Filed: 03/27/2001
• Issued: 01/07/2003
• Est. Priority Date: 03/27/2001
• Status: Expired due to Fees

• Current Assignee: Carlisle Management Company, Nicolon Corporation
• Original Assignee: Carlisle Management Company, Thantex Specialties, Inc.
• Inventors: Mitchell, John G., Carr, Richard W. III, Clarke, Steven R.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): McDermott, Kevin
• Application Number:
  US09/817,995
• Publication Number:
  US 20020139076A1
• Time in Patent Office: 651 Days
• Field of Search: 52/901, 523/021, 524/08, 524/09, 527/414, 527/450.6, 527/452.1, 527/461, 527/461.1
• US Class Current: 52/408
• CPC Class Codes: E04D 5/10 by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
• CPC Class Codes: E04D 5/12 specially modified, e.g. perforated, with granulated surface, with attached pads
• CPC Class Codes: Y10T 428/149 Sectional layer removable

Abstract

This invention is directed to a membrane laminate for a roofing system comprising a membrane sheet and a nonwoven material laminated to said sheet. The nonwoven material has a semi-permeable, skinned layer formed therein.

Claims

1. A flat roof comprising:

a sub-roof system;

a layer of asphalt;

a layer of membrane laminate comprising a membrane and a nonwoven material, said nonwoven material and said membrane being laminated together, said nonwoven material having a semi-permeable, skinned layer formed therein; and

said layer of asphalt adhering said laminate to said sub-roof.

2. The roof of claim 1 wherein said nonwoven material comprises a blend of a structural fiber and a fusible fiber.

3. The roof of claim 1 wherein said nonwoven material comprises a blend of a polyester fiber and a fusible fiber.

4. The roof of claim 1 wherein said nonwoven material comprises a basis weight of about 1 to about 20 ounces per square yard.

5. The roof of claim 1 wherein said asphalt being selected from the group consisting of:

Type III, Type IV, modified, SBS, SEBS asphalts, and combinations thereof.

6. The roof of claim 1 wherein said sub-roof system comprises either a substrate or a pre-existing roof.

7. The roof of claim 1 wherein said membrane further comprises a flexible vulcanized rubber sheet.

8. A method of constructing a roofing system comprising:

providing a sub-roof system;

applying a layer of hot asphalt on said sub-roof system; and

applying a membrane laminate to said hot asphalt, said membrane laminate comprising a membrane material laminated to a nonwoven material, said nonwoven material having a semi-permeable-skinned layer formed therein.

9. The roof of claim 8 wherein said nonwoven material comprises a blend of a structural fiber and a fusible fiber.

10. The roof of claim 8 wherein said nonwoven material comprises a blend of a polyester fiber and a fusible fiber.

11. The roof of claim 8 wherein said nonwoven material comprises a basis weight of about 1 to about 20 ounces per square yard.

12. The roof of claim 8 wherein said membrane further comprises a flexible vulcanized rubber sheet.

13. A membrane laminate for a roofing system comprising a membrane sheet and a nonwoven material having a semi-permeable skin layer formed therein, said nonwoven material adhered to said membrane sheet.

14. The roof of claim 13 wherein said nonwoven material comprises a blend of a structural fiber and a fusible fiber.

15. The roof of claim 13 wherein said nonwoven material comprises a blend of a polyester fiber and a fusible fiber.

16. The roof of claim 13 wherein said nonwoven material comprises a basis weight of about 1 to about 20 ounces per square yard.

17. The roof of claim 13 wherein said membrane further comprises a flexible vulcanized rubber sheet.

18. A method of using a nonwoven material for a membrane laminate used in a roofing system comprising the steps of providing a blend of a structural fiber and a fusible fiber adapted to retard penetration of asphalt into said nonwoven material and to reduce or prevent asphalt volatiles from contacting said membrane.

19. The roof of claim 18 wherein said nonwoven material comprises a basis weight of about 1 to about 20 ounces per square yard.

20. The roof of claim 18 wherein said membrane further comprises a flexible vulcanized rubber sheet.