Document 2qGzzpbdyodDjRgVxgOewyd6b

jan. 31, 1957 FIG. 1 P. S. BETTOU UUfUUTtD SHEET lUTEXIAli Filed Jsa. 21. 1963 3,300,927 FIG. 4 INVENTOR Phillip Stephen bettoh BY Tvc-V attorneys O 1 --02 139914 GAF 22826 United States Patent Office 3,300,927 Fitented Jan. 31, 19S? 12 JJM.W LAMINATED SHEET MATERIAL md SKfloJiMlI, MntlBitillt. NJ, itiliMr t The ftnbnswM Cgnrnr, s mpmiln of Nvw ienwy Pdyvmylfluoridc, having hr struemra] formnil' nn b'iltd Im 21. lMi. Ser. No. 2S2.2M 14 Claim*. (CL 32--J0) and in the fenr. of a plastic film of uniform thickness, is the poiyvinylflunridc used in the laminant rf this inven. This invention relates to a laminaied sheet material lion. It is extremely inert and unreactive, and withsranda for covering and protecting a variety of surface-, and extremes of temperature and humidity. Moreover, h is non particularly relates to a polyvinylfluoride laninant jg not significantly degraded by ultraviolet nditrioo Beinp with excellent weathering characteristics for use is the flexible and readily available in pigmented form, it is roofing and tiding trades. suitable fo. me with roofs having unusual eomottr or form, fc U aa object of this invention to provide a mste.rfal fo-' example, parabolic roofs which cannot readily be far entrisf and protecting the exposed surfaces cl a cowred with corventtosaj asphaltic materials. It i* also variety of immures. ft is a further chject to provide IS suitable far rooft where a particular color is desired. with a flexible roofing or sidiap material which can be used out the <l>vi.o>aniape rf bavin; to paint the same. It is on sorbets havine irregular or unusual contours. The not practical to ue pclvxi.-.tlfluorij* film alone, however. material of this invention, polyvinylfluoride plastic S!m The thkLnevs of the Aim. usually I to 4 miH, presents laminaied to a non-flammable. elastomerie-impregnated hanJJinp and working problem-. Used alone, it cannot be asbestos felt hacking. has excellent werthenng Chirac- so handled with available mofinp tools arcordinp to esrab- irrada and win nor erode, crack or enrr upon lor.p ea- li'had techniques. In -dj.iiox adhesives available lor posurt to visible or ultraviolet radialion or climatic ex treme* of temperature or humidity. It hat excellent di on-vite applicautn to rs.rf and the like, are inadequate for producing a tati-fsetpry bond between the men files mensional suibtlity end substantially permanently remains and the surface to which it is applied. srronp and flexible under all climatic conditions. In uUi. SS Rt.'errinp to FIG. I du laminant 10 of this invention (ion. the p'cmaued ceverfnp material of this invention comprises prlyvinylflurride plastic film II secured to aa provides a decorative and colorful material has inp durable a-betos b.-cking 1} by meant of a thermoreiting ditto color and one which is substantially stain-resistant. meric adheti-.t 13. The bund berweea film and Icit is b as another object of this invention to provide e rigid permanent. The felt backing 12. which it impteptuted ftrucrural material hrving an outer coserf-p of poly- JO with an elastomer, preferably neoprene, is al-0 flexible. vinytfluoridt plastic fBm. far use in tl<e building index, The combination ef ICm and felt backing obviates the which incorporates the advantage* of the laminated sheet handling uiflicultiev refr-rtd to above and enable* the material described in the preceding paragraph. laminant 10 to be <J to surf-iecs wish the usual h is a further obirct of this invention to provide a avphali-c type ad:-..-i.-v. Moreover, the Latinant has roof bavinp a roof deck covered with a laminant su- 3S ircrca-ed re-ivtan.c 10 oteha.-tienl damage. pjnctnres and serial which is less than one--isth Hie wrichl of a eon- tears, re which the un-ap.-orred pnlwinylfiouiide film vrminnal built-up roof coverinp. and which pt-evatt wo:d othimive Sc p -r.-tlaily vuvceptiblc. the dc-irahfe characteriviics of beinp non-flammable and Biri.-rcp-intpree.i-.e-i fe'n are unv.i>*f.ctnry a* e back of not drprxfinp with ape or upon einosure to climatic ing mate--! fer polys inviiu-ride. They can came tamo estremes of weather, in its pigmented form, the laminant 44 staining of the photic S'm. but mrre impnnamly. they are material retains its color aid docs noe reeuire periodic nr bream. flexible. uvsaTy ymbntilc on aging and are paiminp. Moreover, the mechanical strength and flexi inflammable. El.-romerc-impregnated felt. on the other bility of the laminant accomodates tivelf to the expansion hard, rrirrin* sub-tantrl'y permanently flexible on ex- or contraction of the underlying roof deck. p.wure to cilmalie evirttr-ev of temperature and humidity. These and other objects urplicit in this speciflcation are 44 Proper selection of the elavinmer will vivid a neisdlans- accomplished, in peneraL by the advantageous use of a maMe laninant. In this regard, polychloroprene I Du laminant comprisinp a polyvi.vy Ifluoride rle-tic Slot ad Pont neoprene) is the preferred efavinmerie timfrr for hesively secured to an asbestos fe't backing which has the laminant of this invention. Si net poly v.tn Ifluorxle been imprrpnated with an elaslomeric binder, such as plavric film is aJva nen-'emmabte. the maltt-nr laminant pirlychlcroprcnc. neoprene and poiyvinylaceiate. poly- ^ (with the non-flammib> pnltfhlorDprrne-imgrcgnated chloreprene and acrv lonitrilc or polychlororrene and backing) will pov<vs *bit devi-nMe chiractcristie. O'her ether elastomeric additives which yield a noa-Sanmahle ncn-fl:.mmable elastomers, including misturei of poly, product. The p-dyvint Ifluoride film is pigmented, yield- chlorepretre and polys.rvlaeetate er pnlychloroprene and mp s decorative, colored laminant material. Thepirment- other nor-flammaMe additiwrv may also be tried to im- ed Atm is vub-tantiully opaque to incident ultrario'es and ** pretmte the avbevin* felt. N.-m-fiammablc mixtures Of visible radiation and protects the elas'o.-ncr-imprtpnated polychloroprrne and aryloniinie or other riastomrrie backin; and under-structure from po*...Me photochemical binders are also suitab'-e. In any cave, the impregnated degradation. The laminant may be used atone as a product should be non-flammable (by wh'ch teem is mean soofiep or sidinp material or it may be combined with either non-combustible or irlf-eslinguivhing) providing a suitable ripid slab* of insulatinp material for use generally * material having an wjvxcuge over inflammable prior art as a coverinp material for buildings. products, tuch as bitussen-saiuraied felts. In the accompanying drawing*. FIGURE 1 is a cross, Asbestos fell is the preferred material foe are in the sectional view of the laminated material of this iavciw laminant product of this invention. Organic felts or lion. papen have been found to lick di.men-ioul debility ard FIGURE 2 k a plan view of a section of a roofing * flame rrsiscanoe. They also embrittle and degrade with material embodiment of this ic-rentiou; age. Glare fibers are d^firult to bond to pofyeiny iHfoeidB FIGURE J is plan view of a roof with portion* of and lack desirable elcneatios cheracrerssiew Ahsminum the recflnp material broken away in show the disposition foil docs not provide optimum handling chereeteristia of the laminated material of this iavcnlioe: and od is susceptible to mechanical damage. ESa-tomcric- FIGURE 4 is a cross icciional view of a ripid structural 7 impre^tated atbettos feh is preferred over ord nary. w material of this invention. saturated asbesxos paper, which is not suitable aw a hack- 1 I t r. I t 01-0213995 GAF 22827 3,300,M7 6 boot | niL Tool mil* thickaetx ii approximately the it may ba laminated, in turn, to a suitable, rigid insulating upper Sait, taking factors si economy and film maau- substance for me as a corertnc material wtiere rigidity Iicturitig speaftcaiioro into consuferusoa. Should tla is a desired characteristic, as ia siding* for buildings. Umieant be applied to area subject to heavy traffic. a 4 In the production of flexible roofini matenal 14 tbe out later nf polyvmylfluoridq film would be preferable. film and tell are preferably trimmed and cut in prerietcr- -" Curing-Type elatotnerie adhesives an utiiabla for Isaunating polyvmyUluonde securely a the saturated a- mined widths. The final product thus obtained is tbowa in FtG. 2. Film il is applied to the left 12 in a bcstne fek backing. An acrtlocilriie adhesive with phe- manner such that, in the final product, tbe tongbud*. nolk tackifiers and an isocyanate eunn( ag-nt n perl ape nal edge of the Him IS defines a selvedge It of a uniform most suitable and may be regarded as yielding optimum m width. Selvedge 14 permits overlapping of tucceisivn results, la feacnl, any elastomeric adhesive may be uied lengths of rooting material as described belw. |i also al which rrtains its flexibility and will not undergo minift* lows for the bonding of asbestos fell on asbestos frit, aod cation upon long exposure to light or climatic extremes. not felt on potyvinylfluoride. Hence, a wide variety of Pclysalhix sd.nes.ves. although expensive and diScuit to adhesives, including bitumen cements may be used, handle. are also suitable. is Roofing material of a standard width may also be pro Elauomerie saturated asbestos 12 is manufactured ac duced without providing a film-free selvedge 14. should cording to established techniques with tbe components this be desired. ard in the quantities stated above. The following exam Referring now to FIG. 3, application of the roofing ples are included for purposes of Sttmmion. it being un material shown ia FIG. 2 will be described. FIG. * de- derstood that other ingredients are also useful to provide to piers a standard wood roof deck 17 which is mopped wnh the laminin material of this invention. roofing asphalt It (12 lbs..'ICO q- ft.). It should bn Eiampi* I understood that the roofing material of this invention may be applied to a variety of roof decks, including decks of Fofychlorrprette was slurried ha a paper maker's heater wood, concrete and insulation. It may also be applied at aDots 60-70* F,, along with a dispersing agent, aa tS by a variety of means, including cither hot asphalt or cold iniMUuiS. Zinc oxide and alum, the latter having been Cement application*. Conventional coaled, sanded oaj added to precipitate the potvchloroprcne. The poly- asphalt-taturucd base sheet 19-22 is applied to deck 17 chloroprene was added in the form of a 20* solids latex which has been asphalt mopped. The base sheet is ap (Os Font Neoprene Lt-tex 725.) Additions of alum plied in successive lengths 17. 23. 21 and 22. with one ere made at the beater head bot to control foam and ot length <21 for example) overlapping the preceding tub- to maintain an acid p-H. Pols ch'orogrene latex was a-Jded jacent length (20) by about 4 inches. The base sheet ia sufficient quantity to provide a Cabled product con is nailed according to cuablisheti techniques. taining lO'r polychlaroprenc solids. Lamination of the Roofing material 14. having a tclsedge 14. as shown pui) vruyifiuorije plastic film II to Uw polychlororren* FIG. 2. is applied ir. a manner similar to base sheet 19t saturated fell bucking 12 wax accomplished with a nitrile- 33 via., by mopping and apply iig overlapping lengths of phenolic adhesive l Du Pont Modified Synthetic Rubber ror-ilnp material 14. Il.ux. the a ea to be occupied by Adhesive lyre *634. contauutr; HFe DuPont Curing Ictivh 23 of roofing material 14 ia mopgrd with roofing Aecat RC tU51. to which 4'i by weight of aqueous car- atphait 24 <20 lbs./100 sq. fu) and a length 23 it laid. '. nit black had been added. The laminating adhesive was An i-rra adjacent the lergth 23 is also mopped with auimted to a viscosity cf 16 to I* |uhn cup No. 3) with ** pa rut. The selvedge 16 of Ivrgth 23 is also mopped methyl ethyl ketone, and the coi-.ieg rod employed for the to *:ihir one inch of the longitudinal edge 15 of the poly- lamination operation was adiuslcd to apply the equivalent vinyifluoridt film It. A next length 25 of roofing mate of 0J mil of dry aJItoive solids. The aJhcsivc was sp- rial |4 n then laid with an edge 26 thereof comp'ctely plied d'teetly to a roiyvinylfluor.de Elm of 2 mils thick covering the selvedge 16 of the first length 23 and super- ness. the film then being petted through a drying tower 43 concent the some. Successive ienytha are applied in the to emote a portion of the methyl ethyl ketone. The tame fashion, care being takes that the selvedge 16 of film II was laminated to the smooth aide of the poly- each length is mopf-cd only to a maximum cf one inch cMotcpreae-impregnaled frit barking 12 by a convert- away from the longitudinal edge IS. This win insure tiunal nip roil laminating operation. Tbe nip roll wax that avg.halt 24 dues not ooae out onto the exposed tur- maintained al 200* F. and 120 p.xi. Machine treed wax 43 face of the material 14. The end result of overlapping about ISO feet per minute. lAt speed* hctrnv ISO feet successive len-'tu of roefin- iraierisl 14 is shown in per minute. the temperature tlmuld be reduced to ISO* FIGURE ) al lengths 27 and 2*. The operation may be F.) The laminated product 16 was thee subjected to completed by scaling the -elms between overlapping acditiooal beat and to a high velocity air stream to re* Irngths (;.e., end laps 29 xr.d tide laps 30) with a pres- mere the remainder of (he laminaling solvent from tbe 33 su-e-scnsi'-i-a ti^e. preferably r similarly pigmented poly finished product. vinyl (1uur.de pm;ic film. Th* scams may also be closed Ezamplt J with a siiitone ct.ull.ing compound or suiuale polysulfide A slurry of asbestos was made in a beater under the conditions and with the ingredients described in Example I. except that in place of poiych'oroprcne. a mixture of ro'yehiuroprenc and polyviaylageia'e in tbe weight ratio of ):l was charred to the beater. The amou.it in.ro- M ruabrr cements. A roof to which a preferred pigmented white film roofing muterivl 14 hat been applied hat a rrficetivi y up wards of 75^2 and is csmplctely waterproof end vaporproof. di-ced was tuffic.cai to pruouce a product having UrV by weigh: of the elastomeric mixture. Lami.tation wx; carried out ia the manner described ia Example I. A -re by weight addition of carbon b'ack was mad* to 'he adhesive prior to Ummatiua and the coaling roll was ad justed in apply the equivalent of OJJ mil dry adhesive 63 Variations of the abeve methods may be employed is order to adopt the product of this inve-tion to sarious environments or to use the product with other mopping m. .:riats. turn as a cold method cxmenu For example, a gre-cast concrete roof deck may be coated with the roofing material 14. by limply priming with a suitable concrete p-imer and thes apply ing the roofing material solidv The moiling product waa non-fiamme B!e. flex 76 14 dreectly thereto with conventional roofing bitumens. ible and otherwise suited to the variety of utes to which Should it be desirable, t roofing material without tbe thelamuunt of (bis iovemioa may be put. selvedge may also be etr.plr yiA In this cite, lengths of Toe laminate marerial produced in either of tfw ways material 14 art r.ot overlapped and the longitudinal edges detailed above, or ia oilier wys mxy be further proc- of the successive lengths of material merely abut each eased for use as a flexible roofing or tiding matenal; or 73 ether. The seams are then sealed with polyvinylfluonde 31-0213996 GAF 22828 S,300,097 78 pintle tspa^tiJicooe caulking compound or potysulfide polyvinyifluoride plastic film Waving a uniform thickness rubber cement. of at least about ere mil, and an asbestos fell backing kefereing to FKJ. 4, a product for use m covering aod impregnated wuh (iota about 15% to abcut 25% by protecting structures may be made by securing the Uim> weight of priythtoroprene. said film secured in said earn 10 df Utia invemicn to a rigid slab of insulating ms* fi asbestos felt backing by means cf a themtesettisg elaw lerial 3J with a suitable adhesive 32. such as asphalt or tomenc adhesive. the-htc. The laminant compmes a laytr of pelyv'ryl- 9. A roof in accordance with ciaira t w herein the width fluoride pknite film II adhesively secured (by means of of said polwieyifluoridc plastic film is less than the width adhesive 131 to clastomer-impregnaied asbestos 13. The of said barking -uch that a film-free cdf* of airifcrm felt backing 12 is secured to the insulating material, pro jQ width is defined by the longitudinal edge of tcid film, ducing a structural materiel w herein the polyvinylfluoriJe said roofing material being disposed on said rncf deck film II is the eapesed surface. The rigid slab 31 may he in overlapping fashion such that a superadja-nt length manufactured from a variety of conventional insulating of said roofing material coven the said Mai-fret edge of materials which have been found to be useful in the build a subjacent length of said roofing material, anj wherein ing trades, such as wood, including shredded wood, wood U the seams between said length of roofing materials are shavings, excelsior, or paper, newspaper, vcrmiculite. sealed with pressure-vt.vitire adhesive tape, said tape gravel, stones, cement or cement witb light aggregates. comprising polyvinylfluoride plastic film. I claim: IS. A roof comprising e roof deck and incentive t. A material for covering and protecting the exposed lengths ef flexible roofing material having a uniform surface; to structures comprising a substantially opaque tO width, said material covering saJ mef deck. ta:d roofing poiyvmv Ifluoride plastic film of low light transmissability malarial being weather and fire re-otant and uniformly having a tuuform thickness ef at least about one mil and secured to said roof deck with an asphaltic adhesive, said an asbestos fed backing impregnated with polychloro- roofing materia! comprising pipmrated suSurtially prene. said polyvinyifluoride plastic film having uniform opaque polyvinyifluoride plastic film having a uniform ly incorporated therein up to 25% by weight cf aa opacify U thickness ef at least about one mil. and an ashevos felt ing pigment, said film adhesively secured to said backing backing impregnated with from about 15% to about 25% by means of an elastomeric adhesive of low light tram. by weight of potychleroprene. said film secured to said nuuabiii:>' containing up to 10% by weight of opaefyiug asbestos fell backing by means of a iheimmeuiag elas pigment. tomeric adhesive containing up to 10% by weigh: of cap- 2. A weather end fire resistant moling material com 30 bon black. prising a polyvinylfloeride plastic film adhesively lami It. A roof comprising a roof deck and ncauin nated to aa asbestos felt backing by means of a thermo* lengths of fleeil *e roofing material haring a uniform setting elastomeric adhesive, said asbestos felt backing im width, said material covering -aid roof deck, said roofing pregnated with a non-flammable eiauoir.cric binder, and material being we-.ther ami fire roalint and uniformly said gbstie Elm being substantially opaque to protect the adhesive hood thereof to the backing from photochemical 3d secured to s--d roof deck with *c asphaltic idliesive. said roofing mater^l crmprlsing a pitmemed substantially degradation. opaque .--oiyvinylltiaoriJe plastic film having a uniform 3. A flexible roofing material comprising an asbestos felt backing impregnated with froo about I JIT to about thickness of at least one mil, and . v a-bestos felt backing impregnated wi-h frum about I f te about 25% by 13% of polych'oroprcne and a polyvirylfluorhie pbvttc W weight of poKch'oropreee, * X fi'm secured to said film having a uniform thickness of it least about one mil asbestos leh bucking by mesas c -. thermowning, elas- second to said asbestos fell backing r-y means of a thermo- tomene adhesive, said rc-ding ;r.i>'.rul disposed cn said settles elcstamerie adhesive, said film having uniformly roof deck in a manner iu:h that u longitudinal ev're of incorporated thereto up to 25% by weight of pigments one of arid lengths of roofing ir.au rt-l abuts the loots- comprising carbon blade and being substantially opaque. 45 ludinal cJ;e of soother of said lei gihs adjactst to it, the 4. The roofing material of claim 3 wherein the elas scam defined by said abutting luspitcdiaal edges being tomeric adhesive contains up to 10% by weight of carbon scaled by pressore-sensitise adhesive tape, said tape com tlack. prising Myvinylrtuoride plastic film. 5. The roofing material of claim 3 wherein the asbestos 12. A structure for cevenits tcriucei compiling a rigid felt backing is impregnated with from about 13% to about Ig slab of aa insulating material from the group 25% by weight of potychloraprene. 4. A we.ther and fire minuet flexible roofing mate consisting of wsiod. shredded wc.sj. wood shavings, ezcclsiur, paper. vcrmiculite. gravel, cement and cement rial comprising aa asbestos felt backing impregnated with wild light aggreptes incorporated therein, said slab from shout 13% to about 25% by weight of a mixture covered with a weather and fire resistant .heet material containing ote pan by weigh: ef polychloroprenc and up gg comprising an asbestos fell harking adhesively secured to one part by weight ef acrylor.iirile, and a pigmental to said slab, said asbestos felt backing impregnated with subnaniialty opaque polyvinyifluoride plastic film hav ing a uniform thirteen of at least about one mil secured from about 13% to about 25% by vcigbi ot polychloroprene. and a pigmented substantially opaque polyvinyl, to said asbestos fell backing by mesas of a thermateiting fluoride pia'tic film having a uniform thickness of si Iran elastomeric adhesive. gO one mil, said film secured to said bulking with a thermo 7. A weather and fire resistant flexible roofing mate rial comprising aa asbestos felt backing impregnated with setting elastomeric adhesive containing up to 10% by weight of carbon black. from about 15% to abo>it 25% by weight of a mixture containing polycMoreprcne and polyvir.y laertaic in the 13. A weather and fin resistant material for corering tnd protecting the eiposed surfaces cf structures comj prising a laminate cf polyvinyifiuaridc riasuc film secured weight ratio of about 3 to I. and a pigmented substan by an elastsmrnc adhesive to in abe*'pv fell hacking up- tially opaque polyvinyifluoride plastic film having a uni prigameJ wuh a tiun-fkimmabie elastomeric binder, said form ibickneta of at lean about one mil secured to said asbesioi felt backing by means of a thermosetting elas plastic (Urn being substanl.altv oraaue us proiert tu* ad hesive bond thereof lo tba barking 'rort photochemical tomeric adhesive. TP degradation. fi. A roof comprising a roof deck and flexible roofing 14. A structure for covering surfaces comprising a rigid materia! covering bid -oof deck, said roofing material slab of insulating material covered wi:b a umber and bea-g wellher and fire tesistvu and uniformly secured fire resistant sheet materi.1 compiling an asbrsiot fed to said roof deck wits an asphaltic adhesivr. said roofing backing impregnated with a non-Samnublt elacocerie material comprising a pigmented substantially opaque T9 binder and a pigmented polyvtnylfluonoe plastic film se- 01-0213997 GAF 22829 3,300,037 9 10 cured to umI backing by a ihcrmovtting tfavmnmc adhcuc, raid flattie film being wbsumiaOy opaque to pr icct the adhnive bond thereof to the backing bom photo chemical depiditica. 579.626 FOREIGN PATENTS 7/1959 Canada. OTHER REFERENCES thfcdaen Cited by the EmIm American Roofer ana Building imyrotemeat Com.-sctor. TH 2431 .A 1 -A3,, October 1962. page 14. MUi.-JS 2.164.790 2.576.854 UNITED STATES PATENTS Modern Pfaalin, TP986.AI.M6, October I9J9. p;pi ( '!* Harvhberprret aL_______!2-->1* 7/ 1939 Smith_______________ 52--409 X 89-91. 200. Modem Ptawica. TP986.AIM6, September 1961. -- 5/1945 Srundcnlit--:05 X M 45. l74,*52 2/1959 Wilton32--I9 3.056.224 10/1942 Atmy $L ________ 161--205 X 3.133.854 3/I964 SimmaiI6t--119 FRANK L. ABBOTT, Primary Examiner. A. C. PERHAM. Aaijxfunf Examiner. 5.223.825 1/1966 UuU rt aL____________161--116 07-0213998 GAF 22830