111111
`
`1111111111111111111111111111111111111111111111111111111111111111111111111111
`US 20060292945Al
`
`(19) United States
`c12) Patent Application Publication
`Kuhn et al.
`
`(10) Pub. No.: US 2006/0292945 Al
`Dec. 28, 2006
`(43) Pub. Date:
`
`(54) ALTERNATE/REDUCED SCRIM FOR
`SINGLE PLY ROOFING MEMBRANE
`
`(75)
`
`Inventors: William P. Kuhn, Stonington, CT
`(US); Edward Nebesnak, Mine Hill,
`NJ (US); Li-Ying Yang, Whippany, NJ
`(US)
`
`Correspondence Address:
`GAF MATERIALS CORPORATION
`Attn: William J. Davis, Esq.
`Legal Department
`1361 Alps Road, Building No.8
`Wayne, NJ 07470 (US)
`
`(73) Assignee: BUILDING MATERIALS INVEST(cid:173)
`MENT CORPORATION
`
`(21) Appl. No.:
`
`111168,954
`
`(22) Filed:
`
`Jun. 28, 2005
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`(2006.01)
`B32B 27112
`(2006.01)
`B32B 27102
`(2006.01)
`B32B 27104
`(52) U.S. Cl. ................. 442/38; 442/20; 442/27; 442/41;
`442/43; 442/45; 442/46; 442/49;
`442/50; 442/54; 442/58
`
`(57)
`
`ABSTRACT
`
`A reduced scrim reinforcement is provided in single ply
`roofing membranes having excellent wind uplift perfor(cid:173)
`mance. Also provided is a method for making a roofing
`membrane having the scrim reinforcement incorporated
`therein.
`
`Bestway Exhibit 1017-0001
`PGR2017-00003
`
`

`
`Patent Application Publication Dec. 28, 2006
`
`US 2006/0292945 Al
`
`18a
`
`,-
`
`10
`
`FIG. 2
`
`16
`
`Bestway Exhibit 1017-0002
`PGR2017-00003
`
`

`
`US 2006/0292945 AI
`
`Dec. 28, 2006
`
`1
`
`ALTERNATE/REDUCED SCRIM FOR SINGLE PLY
`ROOFING MEMBRANE
`
`FIELD OF THE INVENTION
`[0001] The present invention relates to roofing mem(cid:173)
`branes. More specifically, the present invention relates to a
`cost-effective scrim reinforcement in single ply roofing
`membranes having excellent wind uplift performance for
`fully adhered roofing systems, as well as a method for
`making a roofing membrane having the scrim reinforcement
`incorporated therein.
`
`BACKGROUND OF THE INVENTION
`[0002] A single ply building membrane is a membrane
`typically applied in the field using a one layer membrane
`material (either homogeneous or composite) rather than
`multiple layers built-up. These membranes have been
`widely used on low slope roofing and other applications. The
`membrane can comprise one or more layers, have a top and
`bottom surface, and may include a reinforcing scrim or
`stabilizing material. The scrim is typically of a woven,
`nonwoven, or knitted fabric composed of continuous strands
`of material used for reinforcing or strengthening mem(cid:173)
`branes.
`
`[0003] These single ply membranes typically comprise
`base (bottom) and cap (top) polyolefin-based sheets (layers)
`with a fiber reinforcement scrim (middle) sandwiched
`between the other two layers. The scrim is generally the
`strongest layer in the composite. Other materials from which
`the membranes may be formed, include but are not limited
`to, polyvinyl chloride (PVC), chlorosulfonated polyethylene
`(CSPE or CSM), chlorinated polyethylene (CPE), and eth(cid:173)
`ylene propylene diene terpolymer (EPDM).
`
`[0004] A typical method of preparing these membranes
`comprises the steps of unwinding a support sheet, scrim or
`stabilizing material, coating the support by extrusion of a
`molten compounded polymers, adding one or more fillers,
`cooling and solidifYing the membrane, and winding the
`membrane into a roll.
`
`[0005] Currently, the single ply membrane market uses a
`scrim reinforcement of 9x9 1000 denier scrim. Denier is a
`measure of weight in grams per 9000 meters of yarn. 9x9 is
`the number of strands per inch in the MD (machine direc(cid:173)
`tion) and CMD (cross machine direction). However, the cost
`of the scrim in the single ply membrane can be significant,
`as thermoplastic olefin ("TPO") becomes a commodity in
`the industry.
`
`SUMMARY OF THE INVENTION
`[0006] The present invention relates to a scrim having
`substantially the same wind uplift performance as existing
`scrim but which utilizes less scrim when incorporated in
`membranes. The scrim is typically of a woven, nonwoven,
`or knitted fabric composed of continuous strands of material
`used for reinforcing or strengthening membranes. More
`particularly, the present invention provides a 6x6 1000
`denier polyester scrim for incorporation in a single ply
`membrane. The 6x6 1000 denier scrim in accordance with
`the present invention costs less than the presently utilized
`9x9 1000 denier scrim and does not lose any wind uplift
`performance based on the reduced number of strands per
`inch in the MD (machine direction) and CMD (cross
`machine direction).
`
`[0007] Those in the roofing industry understand the impor(cid:173)
`tance of scrim reinforcement on wind uplift performance of
`mechanically attached system. Mechanically attached mem(cid:173)
`branes utilize screws, plates, battens, nails, or other mate(cid:173)
`rials to secure roofing materials to a roof surface. The wider
`the roofing membrane, however, the stronger the reinforce(cid:173)
`ment required to maintain the same wind uplift performance.
`The conventional manner of increasing scrim strength is by
`increasing the denier of the filaments or increasing number
`of strands per inch.
`
`[0008] For the fully adhered roofing system in which the
`membrane is fully attached to the roof surface, scrim
`strength requirement is significantly less to achieve the same
`wind uplift performance as in the mechanically attached
`roofing. For fully adhered roofs, a water or solvent-based
`adhesive may be field applied to secure the membrane to the
`substrate. Alternatively, the membrane can be supplied with
`a factory-applied adhesive with a release liner. A typical
`solvent based adhesive is a solvent based butyl rubber and
`aliphatic/aromatic hydrocarbon adhesive. An exemplary
`water-based adhesive is water-based vinyl acetate adhesive.
`A factory-applied adhesive tape may be a butyl type of hot
`melt adhesive in the thickness of 5-15 mils.
`
`[0009] Accordingly, a single ply roofing membrane is
`provided, comprising a top layer of a membrane, a bottom
`layer of a membrane, and a reduced scrim positioned or
`embedded between the top and bottom layer. The reduced
`scrim is in the range of from approximately 6x6 to 9x9 1000
`denier scrim. Preferably, the reduced scrim is 6x6 1000
`denier.
`[0010] The present invention is also directed to a method
`of preparing a roofing panel having a reduced scrim, the
`method comprising the steps of: unwinding a first layer of a
`membrane, unwinding a 6x6 1000 denier scrim upon the
`first layer of membrane, coating the scrim by extrusion of a
`molten compounded polymers, optionally adding one or
`more fillers, unwinding a second layer of a single play
`membrane upon the scrim; cooling and solidifYing the
`membrane, and winding the membrane into a roll.
`
`[0011] The above and other features of the invention,
`including various novel details of construction and combi(cid:173)
`nations of parts, will now be more particularly described
`with reference to the accompanying drawings and pointed
`out in the claims. It will be understood that the particular
`device embodying the invention is shown by way of illus(cid:173)
`tration only and not as a limitation of the invention. The
`principles and features of this invention may be employed in
`various and numerous embodiments without departing from
`the scope of the invention.
`
`BRIEF DESCRIPTION OF THE FIGURE
`
`[0012] These and other features, aspects, and advantages
`of the apparatus and methods of the present invention will
`become better understood with regard to the following
`description, appended claims, and accompanying drawings
`where:
`
`[0013] FIG. 1 illustrates one embodiment of the scrim in
`accordance with the present invention; and
`
`[0014] FIG. 2 is an exploded perspective view of a scrim
`positioned between top and bottom layers of a single ply
`membrane.
`
`Bestway Exhibit 1017-0003
`PGR2017-00003
`
`

`
`US 2006/0292945 AI
`
`Dec. 28, 2006
`
`2
`
`DETAILED DESCRIPTION OF THE FIGURES
`
`[0015] Although this invention is applicable to numerous
`and various roofing structures, it has been found particularly
`useful in the environment of single ply roofing membranes.
`Therefore, without limiting the applicability of the invention
`to single ply roofing membranes, the invention will be
`described in such environment.
`
`[0016] With reference now to the drawing, the compo(cid:173)
`nents of the present invention will be described. FIG. 1
`shows a sheet of scrim 10 in accordance with one embodi(cid:173)
`ment of the present invention. In FIG. 2, scrim 10 is shown
`as it would be positioned between an upper layer 12 and a
`lower layer 14. Upper layer 12 and lower layer 14 are
`generally cohered to each other with the scrim 10 sealed in
`between to form membrane 16. Layer 12, 14 are generally
`flexible materials and may include, but are not limited to,
`polyolefin-based sheets, as well as polyvinyl chloride
`(PVC), chlorosulfonated polyethylene (CSPE or CSM),
`chlorinated polyethylene (CPE), and ethylene propylene
`diene terpolymer (EPDM).
`
`[0017] Layers 12, 14 may also be thermoplastic mem(cid:173)
`branes preferably polyvinyl chloride (PVC) and other res(cid:173)
`inous compositions containing polyvinyl chloride, chloro(cid:173)
`sulfonated polyethylene (CSPE or CSM), chlorinated
`polyethylene (CPE), ethylene propylene diene terpolymer
`(EPDM), or a thermoplastic olefin (TPO).
`
`[0018] Typically, membrane 16 is a single-ply TPO, with
`an intermediately embedded reinforcing low-stress weft(cid:173)
`inserted fabric in which the mounting area is along a
`longitudinal, warp-thread directional edge of each mem(cid:173)
`brane.
`
`[0019] The typical thickness of membrane 16 is in the
`range of from 0.030 to 0.1 inches. In one embodiment, each
`layer 12 and 14 has a thickness in the range of0.015 to 0.050
`inches, and is formulated from TPO resin. Each oflayers 12
`and 14 may include and contain in the extrusion mix UV
`stabilizers, antioxidants, and fire retardants, such as taught in
`U.S. Pat. No. 6,544,909, which is incorporated by reference
`herein in its entirety. Membrane 16 is in the range from
`approximately 3 feet to 12 feet wide and 100 to 600 feet in
`length. Layers 12, 14 may be provided with a top compo(cid:173)
`sition that provide durable exterior protection. Examples of
`top compositions include compositions having intumescent
`and reflective properties.
`
`[0020] Scrim 10 is generally formed from strands 18a,
`18b, and 20 which are parts of a fabric reinforcing layer.
`Strands 18a are in the warp (length) direction and strands
`18b are oriented in the weft (cross machine) direction or 90
`degrees to the warp strands 18a. Strands 18a and 18b are
`stitched together at the crossing point by the tie strand 20.
`Scrim 10 is typically of a woven, nonwoven, or knitted
`fabric composed of continuous strands of material used for
`reinforcing or strengthening membranes. Low-elongation
`strands can be provided in the direction parallel to one pair
`of membrane edges. The plastic resin composition can
`consist of chlorinated polyethylene containing titaninm
`dioxide and no plasticizer and/or a foraminous, stressfree
`reinforcing layer. The membrane may be a single-ply TPO,
`with an intermediately embedded reinforcing low-stress
`weft-inserted fabric in which the mounting area is along a
`longitudinal, warp-thread directional edge of each mem-
`
`brane. The ultra-high-molecular-weight polyethylene
`(UHMWPE) threads can be warp strands and the mounting
`area can also include warp threads of lower tenacity and
`lower breaking strength, fill threads being throughout the
`membrane of lesser breaking tenacity than the ultra-high(cid:173)
`molecular-weight polyethylene strands. The warp and weft
`threads 18a, 18b throughout scrim 10 are singletons of
`500-1500 denier polyester or other reinforced fibers. The
`preferred threads are with 1000 denier polyester. Effective
`thread count in this invention is 6x6 throughout (both warp
`and fill) membrane 16, six per inch throughout the sheet.
`
`[0021] Membrane 16 may include one or more molten
`polymers incorporated between layers 12, 14, and may
`optionally include one or more fillers. Molten polymers that
`may be incorporated in membrane 16 include, but are not
`limited to thermopasltic polyolefins (TPO), polyvinyl chlo(cid:173)
`ride (PVC), chlorosulfonated polyethylene (CSPE or CSM),
`chlorinated polyethylene (CPE), and ethylene propylene
`diene terpolymer (EPDM). Exemplary fillers which may be
`incorporated in membrane 16 include, but are not limited to,
`carbon black, titanium dioxide, calcium carbonate and inor(cid:173)
`ganic fire retardants such as magnesium hydroxide and
`alumina trihydroxide.
`
`[0022] While there has been shown and described what is
`considered to be preferred embodiments of the invention, it
`will, of course, be understood that various modifications and
`changes in form or detail could readily be made without
`departing from the spirit of the invention. It is therefore
`intended that the invention be not limited to the exact forms
`described and illustrated, but should be constructed to cover
`all modifications that may fall within the scope of the
`appended claims.
`
`EXAMPLE
`
`Wind Uplift Performance with Reduced Scrim for a Fully
`Adhered System
`
`[0023] A standard single ply TPO roofing membrane was
`made with a 9 by 9 1000 by 1000 weft inserted warp knit
`polyester reinforced scrim. An alternate single ply TPO
`roofing membrane in the present invention was made with a
`6 by 6 1000 by 1000 weft inserted warp knit polyester
`reinforced scrim.
`
`[0024] A standard self-adhered TPO membrane was made
`with standard TPO membrane laminated with the adhesive
`tape on the back. An alternate self-adhered TPO membrane
`was made with alternate TPO membrane in the present
`invention laminated the adhesive tape on the back.
`
`[0025] The adhesive tape is a butyl type of hot melt
`adhesive in the thickness of 5-15 mils.
`
`[0026] Two self-adhered TPO roofing membranes were
`tested for the wind uplift performance according to Factory
`Mutual (FM) standard 4470. The data in the following table
`showed the excellent wind uplift performance achieved by
`the alternate self-adhered TPO roofing membrane made with
`the reduced scrim in invention example. The physical prop(cid:173)
`erties of said self-adhered TPO membrane of the present
`invention also meet the ASTM D6878 TPO roofing speci(cid:173)
`fication.
`
`Bestway Exhibit 1017-0004
`PGR2017-00003
`
`

`
`US 2006/0292945 AI
`
`Dec. 28, 2006
`
`3
`
`Self-Adhered TPO
`Roofing Membrane
`
`Wind Uplift Rating
`(Lbs/SF) Per FM standard
`4470
`
`Standard Example
`
`Invention Example
`
`1-105
`
`1-135
`
`1. A roofing panel, comprising:
`
`a. a top layer of a membrane;
`
`b. a bottom layer of a membrane;
`
`c. a 6x6 1000 denier reduced scrim embedded between
`the top and bottom layers;
`
`wherein the reduced scrim comprises woven, nonwoven,
`or knitted fabric composed of continuous strands of
`material selected from the group consisting of polyes(cid:173)
`ter, polyethylene, polyamide and fiberglass.
`2. (canceled)
`3. (canceled)
`4. The panel as recited in claim 1, further comprising a
`polymer disposed upon the scrim between the top and
`bottom membrane layers.
`5. The panel as recited in claim 1, wherein the top and
`bottom membrane layers are flexible sheets selected from
`the group consisting of polyolefin, polyvinyl chloride
`(PVC), chlorosulfonated polyethylene (CSPE or CSM),
`chlorinated polyethylene (CPE), and ethylene propylene
`diene terpolymer (EPDM).
`6. (canceled)
`7. (canceled)
`8. The panel as recited in claim 1, wherein the panel is
`fully adhered to a roof surface.
`9. The panel as recited in claim 8, wherein the panel is
`fully adhered to a roof surface using adhesive.
`10. The panel as recite in claim 9, wherein the adhesive
`can be field applied or factory applied with a release liner.
`11. A method of preparing a roofing panel having a
`reduced scrim, the method comprising the steps of:
`
`a. unwinding a 6x6 1000 denier scrim, the scrim having
`a top and bottom surface
`
`b. coating the scrim by extrusion of a molten compounded
`polymers and optionally one or more fillers on the top
`and bottom surfaces of the scrim,
`
`c. cooling the membrane, and
`
`d. winding the membrane into a roll.
`
`12. The method as recited in claim 10, wherein the molten
`compounded polymers are selected from the group consist(cid:173)
`ing polyolefin, polyvinyl chloride (PVC), chlorosulfonated
`polyethylene (CSPE or CSM), chlorinated polyethylene
`(CPE), and ethylene propylene diene terpolymer (EPDM).
`13. The method as recited in claim 10, wherein the
`cooling step results in solidification of the molten compound
`polymers coated on the scrim.
`14. A 6x6 1000 denier scrim for incorporation into a
`single ply roofing membrane, wherein the reduced scrim
`comprises woven, nonwoven, or knitted fabric composed of
`continuous strands of material comprised of polyester.
`15. A roofing panel for improved wind uplift performance
`in fully adhered roofing membranes, comprising:
`
`a. a top layer of a membrane;
`
`b. a bottom layer of a membrane;
`
`c. a 6x6 1000 denier reduced scrim embedded between
`the top and bottom layers;
`
`wherein the reduced scrim comprises woven, nonwoven,
`or knitted fabric composed of continuous strands of
`material selected from the group consisting of polyes(cid:173)
`ter, polyethylene, ultra-high-molecular-weight polyeth(cid:173)
`ylene (UHMWPE), polyamide and fiberglass.
`16. (canceled)
`17. (canceled)
`18. The panel as recited in claim 15, further comprising a
`polymer disposed upon the scrim between the top and
`bottom membrane layers.
`19. The panel as recited in claim 15, wherein the top and
`bottom layer are flexible sheets selected from the group
`consisting of polyolefin, polyvinyl chloride (PVC), chloro(cid:173)
`sulfonated polyethylene (CSPE or CSM), chlorinated poly(cid:173)
`ethylene (CPE), and ethylene propylene diene terpolymer
`(EPDM).
`20. (canceled)
`21. (canceled)
`22. A roofing panel, comprising:
`
`a. a top layer of a membrane;
`
`b. a bottom layer of a membrane;
`
`c. a 6x6 1000 denier reduced scrim embedded between
`the top and bottom layers;
`
`wherein the reduced scrim comprises woven, nonwoven,
`or knitted fabric composed of continuous strands of
`material comprised of polyester.
`
`* * * * *
`
`Bestway Exhibit 1017-0005
`PGR2017-00003