Complex synthetic waterproofing membrane with laminated structure and its manufacturing process

Abstract

Complex synthetic waterproofing membrane with laminated structure and method for manufacturing same The invention relates to a complex waterproofing membrane (1) with laminated structure, comprising at least one continuous layer (2) based on polyvinyl chloride (PVC) or thermoplastic polyolefin (TPO), a reinforcing frame (3) at least partially integrated in said continuous layer (2) and a geotextile (4) assembled by lamination with said continuous layer (2). This membrane (1) is characterized in that the face of the geotextile (4) forming the underside of said complex waterproofing membrane (1) comprises an adhesive (5), in a discontinuous layer. Figure to be published with the abstract: Fig.1

Description

Title of the invention: Complex synthetic waterproofing membrane, with laminated structure, and its manufacturing process

[0001] The present application relates to the field of waterproofing membranes, in particular synthetic waterproofing membranes, and relates to a complex synthetic waterproofing membrane, with a laminated structure, and its manufacturing method.

[0002] The aforementioned membranes are in practice applied to supports made of materials of various natures, such as concrete, wood, metal or PIR, XPS or EPS insulation, to which they must adhere strongly in order to resist in particular detachment due to the suction effect of the winds.

[0003] In the state of the art, complex waterproofing membranes with a laminated structure are already known, comprising a continuous thermoplastic membrane, a reinforcing frame at least partially integrated into said thermoplastic membrane and a geotextile assembled by lamination with said continuous thermoplastic membrane.

[0004] However, these known complex waterproofing membranes require, for their installation with fixing on at least some of the supports mentioned above, the prior application of a primer and / or the application of a specific fixing adhesive on said support. In addition, certain insulators, given their possible dimensional variations after installation on site, require semi-independent installation of the membranes to avoid stress concentrations in the waterproofing coating, which would result in cracks. Such installation is tedious and delicate to carry out in relation to a prior application of glue or primer.

[0005] The present invention aims to overcome these drawbacks.

[0006] For this purpose, it relates to a complex waterproofing membrane, with a laminated structure, comprising at least one continuous layer based on polyvinyl chloride or thermoplastic polyolefin, a reinforcing reinforcement at least partially integrated into said continuous layer and a geotextile assembled by lamination with said continuous layer, complex waterproofing membrane characterized in that the face of the geotextile forming the underside of said complex waterproofing membrane comprises an adhesive, in a discontinuous layer.

[0007] The invention will be better understood from the following description, which relates to preferred embodiments, given as non-limiting examples, and explained with reference to the appended schematic drawings, in which:

[0008] [Fig.l] is a schematic sectional view of a complex waterproofing membrane according to the invention;

[0009] [Fig.2] is a schematic sectional view of a roof waterproofing system comprising a complex waterproofing membrane according to [Fig.l];

[0010] [Fig.3] is a schematic representation of a production facility for manufacturing a complex waterproofing membrane according to a first embodiment of the invention and as shown in [Fig.l];

[0011] [Fig.4] is a schematic representation of a production facility for manufacturing a complex waterproofing membrane according to a second embodiment of the invention and as shown in [Fig.l].

[0012] [Fig.l] illustrates, schematically, a complex waterproofing membrane 1, with a laminated structure, comprising at least one continuous layer 2 based on polyvinyl chloride (PVC) or thermoplastic polyolefin (TPO), a reinforcing frame 3 at least partially integrated into said continuous layer 2 and a geotextile 4 assembled by lamination with said continuous layer 2, complex waterproofing membrane 1.

[0013] According to the invention, this membrane (1) is characterized in that the face of the geotextile 4 forming the underside of said complex waterproofing membrane 1 comprises an adhesive 5, in a discontinuous layer.

[0014] Thanks to these provisions, the aforementioned drawbacks are overcome.

[0015] Advantageously, the surface coverage rate of the underside by the discontinuous layer of adhesive 5 is between 1% and 99%, advantageously between 15% and 85%, preferably between 30% and 70%.

[0016] Preferably, the adhesive 5 consists of an adhesive having a glass transition temperature of less than 0°C, advantageously less than -20°C, preferably less than -30°C, for example approximately -34°C, determined by differential scanning calorimetry.

[0017] According to a beneficial characteristic of the invention, the adhesive 5 consists of an acrylic type adhesive, for example a partially crosslinked UV polyacrylic adhesive. The choice of an at least partially crosslinked solid adhesive makes it possible to overcome the harmful effects of possible condensation phenomena (compared to a water-based adhesive in particular) and to provide additional cohesion to the membrane. It may also be noted that, in comparison with a so-called "hotmelt" adhesive, this type of adhesive does not require any primer for the supports in question.

[0018] According to another favorable characteristic of the invention, allowing sufficient adhesion to the support, the adhesive 5 is present on the free face of the geotextile (4), forming the lower face of the complex waterproofing membrane (1), at a rate of at least 50 g / m2, advantageously at a rate of approximately 100 g / m2 to 140 g / m2, preferably approximately 120 g / m2.

[0019] According to a constructive variant combining sufficient adhesion, avoiding the stress concentrations once laid and limiting material costs, it may be provided that the adhesive 5 is present on the free face of the geotextile 4, forming the lower face of the complex waterproofing membrane 1, in the form of regular strips and with a homogeneous covering representing between 30% and 70% in surface area, advantageously approximately 50% in surface area, for example in the form of 5' strips 5cm wide and spaced 5cm apart.

[0020] In accordance with two advantageous embodiment variants of the invention, the geotextile 4 can be formed:

[0021] - either polyethylene terephthalate PET fibers, advantageously with a grammage of approximately 200 g / m2, and preferably incorporates a fiber bonding glue, for example at a rate of approximately 30 g / m2, when the continuous layer 2 consists of a polyvinyl chloride (PVC) membrane, advantageously with a thickness greater than 1 mm, preferably between 1.2 mm and 2.0 mm, and advantageously with a grammage greater than 1400 g / m2, preferably between 1600 g / m2 and 2400 g / m2;

[0022] - either of polypropylene PP fibers, advantageously with a grammage of approximately 200 g / m2, when the continuous layer 2 consists of a thermoplastic polyolefin TPO membrane, advantageously with a thickness greater than 1 mm, preferably between 1.2 mm and 2.0 mm, and advantageously with a grammage greater than 1000 g / m2, preferably between 1900 g / m2 and 2600 g / m2.

[0023] According to another possible advantageous characteristic of the invention, making it possible to achieve a very strong and light membrane 1, the reinforcing frame 3 consists of a glass veil, advantageously with a weight of between approximately 30g / m2 and 100g / m2, preferably between 35g / m2 and 50g / m2, and is integrated into the thickness of the continuous layer 2.

[0024] The discontinuous layer of adhesive (5) on the underside of the membrane (1) is advantageously covered with a protective film which in particular allows the membrane to be packaged in the form of a roll and which is removed during application on site (not shown in [Fig.l]). This protective film may, for example, consist of a polypropylene (PP) or polyethylene terephthalate (PET) film, with a thickness of the order of 80 to 100 microns.

[0025] The invention also relates, as shown schematically in [Fig.2], to a roof waterproofing system 6, comprising at least one waterproofing support 7, possibly an insulation layer 8 placed on the support, directly or associated with a vapor barrier, and at least one waterproofing membrane added to said support or to said insulation layer, system characterized in that the waterproofing membrane is a complex waterproofing membrane 1 as described previously.

[0026] Preferably, the discontinuous layer of adhesive 5 is configured, in terms of type of adhesive and surface coverage rate, such that the wind resistance according to standard EN 16002 is > 5000 Pa.

[0027] The adhesive used also advantageously has, on support materials such as concrete, wood, metal or PIR, XPS or EPS insulation, a peel value according to standard EN 12311-2 which is greater than or equal to 25N / 5cm.

[0028] The invention also relates to a method for manufacturing a complex waterproofing membrane 1 as described above, this method being able to be implemented in two distinct embodiments depending on the nature of the continuous layer 2. Figures 3 and 4 schematically illustrate installations for producing these two embodiments.

[0029] Thus, in accordance with a first embodiment of the invention, illustrated by [Fig.3], the manufacturing method may comprise the steps consisting of:

[0030] - produce a continuous layer 2 in polyvinyl chloride PVC by coating with hot in several phases or passes and with integration of a reinforcement frame 3,

[0031] - provide a geotextile 4 covered with a discontinuous layer of an adhesive 5 on a face,

[0032] - assembling by lamination the geotextile 4 with the PVC layer 2 while this the latter is still hot, that is to say has a temperature of at least 100°C, preferably between 130°C and 140°C.

[0033] Advantageously, the production of the PVC layer 2 by hot coating is carried out in at least three, preferably four, successive operating phases each comprising an operation of coating plastisol 2' on silicone paper 9 followed by passage in an oven at approximately 200°C, with a residence time greater than 1 minute, preferably between 1 minute and 3 minutes, the reinforcing frame 3, advantageously a glass veil of approximately 40 to 50g / m2, being integrated before the second passage in an oven.

[0034] Preferably, the lamination of the geotextile 4 with the PVC layer 2 is carried out at the outlet of this layer from the last oven, said geotextile 4 containing a glue for binding its fibers, of the thermoplastic polyester type, activated by heat and promoting the assembly between the two components 2 and 4 laminated together. The silicone paper is recovered at the outlet of the manufacturing installation ([Fig.3]).

[0035] According to a favorable characteristic, the geotextile 4 is made of polyethylene terephthalate PET fibers, for example with a weight of approximately 200g / m2, and incorporates a fiber bonding glue, for example at a rate of approximately 30g / m2.

[0036] In accordance with a second embodiment of the invention, illustrated by [Fig.4], the manufacturing method may comprise the steps of:

[0037] - extruding a first sheet of thermoplastic polyolefin TPO by means of a first flat die 10,

[0038] - assemble by calendering the reinforcement frame 3 with this first sheet for form a composite sheet,

[0039] - extruding a second sheet of thermoplastic polyolefin TPO by means of a second flat die 10',

[0040] - assembling by calendering the composite sheet and the second polyolefin sheet thermoplastic TPO to form a continuous layer 2 incorporating a reinforcing frame 3,

[0041] - providing a geotextile 4 covered with a discontinuous layer of an adhesive 5 on a face,

[0042] - assembling by hot lamination the geotextile 4 with the underside of said layer continuous 2, formed by the second sheet of thermoplastic polyolefin TPO.

[0043] Advantageously, in the context of this second embodiment, the extrusion of the first sheet consists of a coextrusion of two sheets intended to form the central and surface layers of the continuous layer 2, in that the reinforcing reinforcement 3 consists of a glass veil, for example with a grammage of between 30g / m2 and 40g / m2, in that the geotextile 4 is made of polypropylene PP fibers, for example with a grammage of approximately 200 g / m2, and in that the hot lamination of the geotextile 4 with the underside of the continuous layer 2 integrating the reinforcing reinforcement 3 is carried out at a temperature of between 100°C and 130°C.

[0044] The features and variants mentioned in the following apply to both embodiments of the manufacturing method mentioned above.

[0045] The geotextile 4 can be glued prior to its assembly with the continuous layer 2, or after this assembly.

[0046] In both cases, it is advantageously provided that the supply of the geotextile 4 covered with an adhesive 5 comprises the gluing in a discontinuous layer, advantageously in strips, of said geotextile 4 with said adhesive 5 with a homogeneous covering of between 1% and 99% in surface area, advantageously between 30% and 70% in surface area, preferably approximately 50% in surface area, for example in the form of a discontinuous layer formed of strips approximately 5 cm wide and spaced approximately 5 cm apart.

[0047] More precisely, the adhesive is preferably present on the free face of the geotextile 4, forming the lower face of the complex waterproofing membrane 1, at a rate of at least 50 g / m2, advantageously at a rate of approximately 100 g / m2 to 140 g / m2, preferably approximately 120 g / m2, and consists of an adhesive having a glass transition temperature of less than 0°C, advantageously less than -20°C, preferably less than -30°C, for example approximately -34°C, determined by differential scanning calorimetry.

[0048] Finally, this adhesive favorably consists of an acrylic type adhesive, for example in a partially crosslinked UV polyacrylic adhesive with a glass transition temperature of about -34°C, applied at a rate of at least 50 g / m2, advantageously at a rate of about 100 g / m2 to 140 g / m2, preferably about 120 g / m2, to form a discontinuous layer, for example with a thickness of the order of 0.1 mm.

[0049] According to a first variant of implementation of the method, the latter may consist of providing a geotextile 4 devoid of adhesive 5, of assembling said geotextile 4 by hot lamination either with the continuous PVC layer 2 while the latter is still hot, or with the continuous layer 2 formed by the assembly of two sheets of thermoplastic polyolefin TPO with integration between them of a reinforcing reinforcement 3, of coating the adhesive 5 hot, for example at a temperature between 90°C and 140°C, on the exposed face of the geotextile 4, forming a discontinuous layer.

[0050] According to a second variant of implementation of the method, the latter may consist of providing a geotextile 4 devoid of adhesive 5, assembling said geotextile 4 by hot lamination either with the continuous PVC layer 2 while the latter is still hot, or with the continuous layer 2 formed by the assembly of two thermoplastic polyolefin TPO sheets with integration between them of a reinforcing reinforcement 3, coating the adhesive 5 hot, for example at a temperature between 90°C and 140°C, on a film of polypropylene PP or polyethylene terephthalate PET, for example with a thickness between 30 and 100 microns, forming a discontinuous layer, and finally transferring said discontinuous layer of adhesive 5 onto the geotextile 4.

[0051] In the different variants of the two embodiments of the method for manufacturing the membrane (1), the discontinuous layer of adhesive (5) covering the geotextile (4) on one of its faces is itself advantageously covered with a protective film (for example PP or PET) before the hot lamination phase. This film, useful for packaging the finished product in a roll, will also protect the adhesive (5) during lamination.

[0052] Of course, the invention is not limited to the embodiments described and shown in the attached drawings. Modifications remain possible, in particular from the point of view of the constitution of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims

Claims

1. Complex waterproofing membrane (1), with a laminated structure, comprising at least one continuous layer (2) based on polyvinyl chloride (PVC) or thermoplastic polyolefin (TPO), a reinforcing frame (3) at least partially integrated into said continuous layer (2) and a geotextile (4) assembled by lamination with said continuous layer (2), complex waterproofing membrane (1) characterized in that the face of the geotextile (4) forming the underside of said complex waterproofing membrane (1) comprises an adhesive (5), in a discontinuous layer.

2. Complex waterproofing membrane (1) according to claim 1, characterized in that the surface coverage rate of the underside by the discontinuous layer of adhesive (5) is between 1% and 99%, advantageously between 15% and 85%, preferably between 30% and 70%.

3. Complex waterproofing membrane (1) according to claim 1 or 2, characterized in that the adhesive (5) consists of an adhesive having a glass transition temperature below 0°C, advantageously below -20°C, preferably below -30°C, for example approximately -34°C, determined by differential scanning calorimetry.

4. Complex waterproofing membrane (1) according to any one of claims 1 to 3, characterized in that the adhesive (5) consists of an acrylic type adhesive, for example a partially UV crosslinked polyacrylic adhesive.

5. Complex waterproofing membrane (1) according to any one of claims 1 to 4, characterized in that the adhesive (5) is present on the free face of the geotextile (4), forming the lower face of the complex waterproofing membrane (1), at a rate of at least 50 g / m2, advantageously at a rate of approximately 100 g / m2 to 140 g / m2, preferably approximately 120 g / m2.

6. Complex waterproofing membrane (1) according to any one of claims 1 to 5, characterized in that the adhesive (5) is present on the free face of the geotextile (4), forming the lower face of the complex waterproofing membrane (1), in the form of regular strips (5') and with a homogeneous covering representing between 30% and 70% in surface area, advantageously approximately 50% in surface area, for example in the form of strips 5cm wide and spaced 5cm apart.

7. Complex waterproofing membrane (1) according to any one of claims 1 to 6, characterized in that the geotextile (4) is formed from polyethylene terephthalate (PET) fibers, advantageously with a grammage of approximately 200 g / m2, and preferably incorporates a fiber bonding glue, for example at a rate of approximately 30 g / m2, when the continuous layer (2) consists of a polyvinyl chloride (PVC) membrane, advantageously with a thickness greater than 1 mm, preferably between 1.2 mm and 2.0 mm, and advantageously with a grammage greater than 1400 g / m2, preferably between 1600 g / m2 and 2400 g / m2.

8. Complex waterproofing membrane (1) according to any one of claims 1 to 6, characterized in that the geotextile (4) is formed of polypropylene (PP) fibers, advantageously with a grammage of approximately 200 g / m2, when the continuous layer (2) consists of a thermoplastic polyolefin (TPO) membrane, advantageously with a thickness greater than 1 mm, preferably between 1.2 mm and 2.0 mm, and advantageously with a grammage greater than 1000 g / m2, preferably between 1900 g / m2 and 2600 g / m2.

9. Complex waterproofing membrane (1) according to any one of claims 1 to 8, characterized in that the reinforcing reinforcement (3) consists of a glass veil, advantageously with a weight of between approximately 30g / m2 and 100g / m2, preferably between 35g / m2 and 50g / m2, and is integrated into the thickness of the continuous layer (2).

10. Roof waterproofing system (6), comprising at least one waterproofing support (7), possibly an insulation layer (8) placed on the support (7), directly or associated with a vapor barrier, and at least one waterproofing membrane added to said support or to said insulation layer, system characterized in that the waterproofing membrane is a complex waterproofing membrane (1) according to any one of claims 1 to 9.

11. Roof waterproofing system according to claim 10, characterized in that the discontinuous layer of adhesive (5) is configured, in terms of adhesive type and surface coverage rate, in such a way that the wind pull-off resistance according to EN 16002 is > 5000 Pa.

12. A method of manufacturing a complex waterproofing membrane (1) according to any one of claims 1 to 7 and 9, comprising the steps consisting of: - producing a continuous layer (2) of polyvinyl chloride (PVC) by hot coating in several phases or passes and with the integration of a reinforcing reinforcement (3), - providing a geotextile (4) covered with a discontinuous layer of an adhesive (5) on one side, - assembling by lamination the geotextile (4) with the PVC layer (2) while the latter is still hot, i.e. has a temperature of at least 100°C, preferably between 130°C and 140°C.

13. Method according to claim 12, characterized in that the production of the PVC layer (2) by hot coating is carried out in at least three, preferably four, successive operating phases each comprising an operation of coating plastisol (2') on silicone paper (9) followed by passage in an oven at approximately 200°C, with a residence time greater than 1 minute, preferably between 1 minute and 3 minutes, the reinforcing frame (3), advantageously a glass veil of approximately 40 to 50g / m2, being integrated before the second passage in an oven.

14. Method according to claim 12 or 13, characterized in that the lamination of the geotextile (4) with the PVC layer (2) is carried out at the exit of this layer from the last oven, said geotextile (4) containing a glue for bonding its fibers, of the thermoplastic polyester type, activated by heat and promoting the assembly between the two components (2 and 4) laminated together.

15. Method according to any one of claims 12 to 14, characterized in that the geotextile (4) is made of polyethylene terephthalate (PET) fibers, for example with a weight of approximately 200g / m2, and incorporates a fiber bonding glue, for example at a rate of approximately 30g / m2.

16. A method of manufacturing a complex waterproofing membrane (1) according to any one of claims 1 to 6, 8 and 9, comprising the steps of: - extruding a first sheet of thermoplastic polyolefin (TPO) by means of a first flat die (10), - assembling by calendering the reinforcing frame (3) with this first sheet to form a composite sheet, - extruding a second ... by means of a second flat die (10'), - assembling by calendering the composite sheet and the second thermoplastic polyolefin (TPO) sheet to form a continuous layer (2) incorporating a reinforcing frame (3), - providing a geotextile (4) covered with a discontinuous layer of an adhesive (5) on one face, - assembling by hot lamination the geotextile (4) with the underside of said continuous layer (2), formed by the second thermoplastic polyolefin (TPO) sheet.

17. Method according to claim 16, characterized in that the extrusion of the first sheet consists of a coextrusion of two sheets intended to form the central and surface layers of the continuous layer (2), in that the reinforcing reinforcement (3) consists of a glass veil, for example with a grammage of between 30g / m2 and 40g / m2, in that the geotextile (4) is made of polypropylene (PP) fibers, for example with a grammage of approximately 200 g / m2, and in that the hot lamination of the geotextile (4) with the underside of the continuous layer (2) integrating the reinforcing reinforcement (3) is carried out at a temperature of between 100°C and 130°C.

18. Method according to any one of claims 12 to 17, characterized in that the provision of the geotextile (4) covered with an adhesive (5) comprises the gluing in a discontinuous layer, advantageously in strips, of said geotextile (4) with said adhesive (5) with a homogeneous covering of between 1% and 99% in surface area, advantageously between 30% and 70% in surface area, preferably of approximately 50% in surface area, for example in the form of a discontinuous layer formed of strips (5') of approximately 5cm in width and spaced approximately 5cm apart.

19. Method according to any one of claims 12 to 18, characterized in that the adhesive (5) is present on the free face of the geotextile (4), forming the lower face of the complex waterproofing membrane (1), at a rate of at least 50 g / m2, advantageously at a rate of approximately 100 g / m2 to 140 g / m2, preferably approximately 120 g / m2, and consists of an adhesive having a glass transition temperature of less than 0°C, advantageously less than -20°C, preferably less than -30°C, for example approximately -34°C, determined by differential scanning calorimetry.

20. A method according to any one of claims 12 to 19, characterized in that the adhesive (5) consists of an acrylic type adhesive, for example example in a partially crosslinked UV polyacrylic adhesive with a glass transition temperature of about -34°C, applied at a rate of at least 50 g / m2, advantageously at a rate of about 100 g / m2 to 140 g / m2, preferably about 120 g / m2, to form a discontinuous layer, for example with a thickness of the order of 0.1 mm.

21. Method according to any one of claims 12 to 20, characterized in that it consists in providing a geotextile (4) free of adhesive (5), in assembling said geotextile (4) by hot lamination either with the continuous PVC layer (2) while the latter is still hot, or with the continuous layer (2) formed by the assembly of two thermoplastic polyolefin (TPO) sheets with integration between them of a reinforcing reinforcement (3), in coating the adhesive (5) hot, for example at a temperature between 90°C and 140°C, on the exposed face of the geotextile (4), forming a discontinuous layer.

22. Method according to any one of claims 12 to 20, characterized in that it consists in providing a geotextile (4) devoid of adhesive (5), in assembling said geotextile (4) by hot lamination either with the continuous PVC layer (2) while the latter is still hot, or with the continuous layer (2) formed by the assembly of two thermoplastic polyolefin (TPO) sheets with integration between them of a reinforcing reinforcement (3), in coating the adhesive (5) hot, for example at a temperature between 90°C and 140°C, on a film of polypropylene PP or polyethylene terephthalate (PET), for example with a thickness between 30 and 100 microns, forming a discontinuous layer, and finally in transferring said discontinuous layer of adhesive (5) onto the geotextile (4).

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