Bay Mills Limited

D Mark Woiceshyn

John Frederick Porter

A puncture resisting and processability improving composite for reinforcing bituminous roofing membranes that are free of organic mats. The composite includes a lightweight open grid of over-under construction, the grid having polyester yarns of about 30 to about 300 denier in the machine direction and about 30 to about 300 denier in the cross-machine direction, a yarns per inch count of about 3.times.3 to about 10.times.10 in each of the machine and cross-machine directions, and a dry weight pick-up of about 60 to about 250 parts of binder to 100 parts by weight of polyester in the grid, in which an adhesive that is one of dissolved and dispersed in a liquid is applied to the composite so that the open grid is held together by the adhesive alone. The composite also includes a high strength reinforcing fabric consisting essentially of a non-woven open grid of polyester having no mechanical connections at cross-over points in the grid, which is combined with the adhesively secured lightweight polyester open grid. The lightweight grid and the high strength reinforcing fabric are so arranged and constructed as to have sufficient binder and surface area to hold high strength grids inside bituminous material of a roofing membrane during manufacture of the roofing membrane and to provide a roofing membrane that is free of any organic mat.

Composite for reinforcing bituminous roofing membranes including a

A reinforced bituminous roofing membrane includes a first layer, a second layer, a third layer and bituminous material. The first layer consists essentially of a lightweight, open grid of adhesively bound non-woven fabric in which yarns in the cross-machine direction are held between pairs of yarns in the machine direction, each such pairs of yarns having one yarn that is essentially above the other and each such pair of yarns being coated and bound next to the other by adhesive which accumulates between the yarns of each pair. The second layer consists essentially of a high strength reinforcing fabric, while the third layer consists essentially of a porous fiberglass mat. The bituminous material saturates and contains the first, second and third layers, such that the three layers are completely embedded within the bituminous material and the bituminous material on one side of the membrane bonds through the layers to the bituminous material on the other side of the membrane.

Bituminous roofing membrane including a lightweight grid and over-under

A reinforced, impervious, unitary film and a method for making the same are disclosed. In a preferred embodiment, a film is produced from a layer of weft inserted warp knit scrim and at least one layer of lightweight, porous mat, together being impregnated with a suitable thermoformable plastic in liquid form such as PVC plastisol, then being set and calendered under pressure to deform the plastic and create a continuous, non-porous, unitary film. The resulting product is highly resistant to water absorption and hydrostatic pressure and essentially non-wicking.

Reinforced film and method of manufacturing same

Disclosed is a process of manufacturing a roofing membrane that is free of any organic mat. The process includes selecting a lightweight polyester fabric including an open grid of over-under construction in which fill yarns are held between pairs of machine direction yarns lying essentially one above the other, the fabric including polyester yarns having about 30 to about 300 denier yarns in the machine direction, about 30 to about 300 denier yarns in the fill direction, a yarn per inch count of about 3.times.3 to about 10.times.10, and a dry weight pick-up of about 60 to about 250 parts by weight of binder relative to 100 parts by weight of polyester in the fabric; selecting a high strength reinforcing open grid; and passing the lightweight polyester open fabric, the high strength reinforcing open grid and any additional reinforcements free of any organic mat through bituminous material to form the roofing membrane.

Process for manufacturing reinforced roofing membranes

A reinforced, impervious, unitary film and a method for making the same are disclosed. In a preferred embodiment, a film is produced from a layer of weft inserted warp knit polester scrim and at least one layer of polyester mat, together being impregnated with a suitable thermoformable plastic in liquid form such as PVC plastisol, then being set and calendered under pressure to deform the plastic and create a continuous, non-porous unitary film. The resulting product is highly resistant to water absorption and hydrostatic pressure and essentially non-wicking.

Method of manufacturing a reinforced film

A textile having increased porosity is made by introducing resin and microspheres or other agents for creating interstices between filaments within a yarn. The micropsheres upon heating or other agents push the filaments apart and create interstices in the yarn and bending stresses in the filaments. The resin may then be cured, holding the filaments in spaced apart relationship relative to each other and maintaining the bending stresses in the filaments.

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St. Catharines, Canada

D Mark Woiceshyn