US4390585A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Durable flexible membrane and method of making same
Assignee: BOND COTE Corp
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Filing: 1982-05-05
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Granted: 1983-06-28
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Expires: 2002-05-05
Abstract
Abstract A flexible membrane having a valuable combination of desirable properties is composed of a generally heavy, dense supporting and reinforcing reticulated base fabric constituted of thick, generally loose bundles of multiple continuous filaments arranged in a mechanically interengated reticular array having an overall weight within the range of about 3-12 oz/yd 2 the continuous filaments being of a synthetic polymer having good dimensional stability and high resistance to heat and light; and a solidified base coating composition completely impregnating the interstices of the base fabric and as forming a continuous coating along the opposite sides thereof, the composition having as essential ingredients a PVC resin and a plasticizer therefor in the amount of 35-75% of the resin of a trimellitate ester which exhibits high resistance to separation from the resin and imparts to the coating high flexibility at temperatures at least as low as about -35° F., the amount of the coating composition being preferrably at least about equal in weight to the weight of the base fabric. Preferably, the coating composition exceeds the weight of the base fabric by a factor of two or more, at least one additional layer of such coating composition being applied to each of the opposite surfaces of the coated base fabric and fused into integral relation therewith so as to improve the abrasion resistance, waterproofness, UV resistance, heat resistance and like mechanical properties of the ultimate membrane. The coating composition can contain additional adjuvants of the several types known in the PVC coating field, including supplemental plasticizers, a fire retardant, UV resistance enhancing, opacifying pigment, fungicidal and like agents. In its optimum form, the present membrane exhibits special utility as a roofing fabric of exceptional durability.
Inventors
- 👤 Durrell W. Holden
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 10:42
CPC Classifications
D; D06; D06N; D06N3/00; D06N3/04; D06N3/06; Y; Y10; Y10S; Y10S428/00; Y10S428/907; Y10S428/92; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24612
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
170 words
A durable flexible membrane comprising: (1) a generally heavy and dense supporting and reinforcing reticular base fabric formed of thick generally loose bundles each containing a large multiplicity of individual continuous filaments of a synthetic polymer characterized by generally high dimensional stability and resistance to heat and light, said multi-filament bundles being arranged in mechanically interengaged intersecting relation with interstices therein, said base fabric having a weight of substantially about 3-12 oz/yd 2 ; and (2) a solidified base coating composition completely impregnating the interstices of said base fabric and continuously coating the opposite sides thereof, which composition consists essentially of polyvinyl chloride resin and as a plasticizing agent for said resin about 35-100% by weight thereof of a trimellitate ester which exhibits high resistance to separation from said resin and imparts to the coating high flexibility at temperatures not higher than about -30° F., said coating composition being present in an amount sufficient to impregnate the interior and form continuous coating on the opposite sides of said base fabric.
Claim 2
Dependent Claim
170 words
A durable flexible membrane comprising: (1) a generally heavy and dense supporting and reinforcing reticular base fabric formed of thick generally loose bundles each containing a large multiplicity of individual continuous filaments of a synthetic polymer characterized by generally high dimensional stability and resistance to heat and light, said multi-filament bundles being arranged in mechanically interengaged intersecting relation with interstices therein, said base fabric having a weight of substantially about 3-12 oz/yd 2 ; and (2) a solidified base coating composition completely impregnating the interstices of said base fabric and continuously coating the opposite sides thereof, which composition consists essentially of polyvinyl chloride resin and as a plasticizing agent for said resin about 35-100% by weight thereof of a trimellitate ester which exhibits high resistance to separation from said resin and imparts to the coating high flexibility at temperatures not higher than about -30° F., said coating composition being present in an amount sufficient to impregnate the interior and form continuous coating on the opposite sides of said base fabric.
Claim 3
Dependent Claim
55 words
The membrane of claim 1 wherein said coated and impregnated base fabric includes on opposite sides thereof at least one additional layer of said coating composition fused in integral relation to the base coating surface, the aggregate weight of said additional layers on both sides equalling at least about 50% of said base coating weight.
Claim 4
Dependent Claim
31 words
The membrane of claim 2 wherein the aggregate weight of said additional layers is divided in the ratio of about 2:1 between the upper and lower surfaces of said base coating.
Claim 5
Dependent Claim
31 words
The membrane of claim 1 wherein said trimellitate ester is a di- or trialkyl ester each alkyl group of which contains at least about 6 carbon atoms in a straight chain.
Claim 6
Dependent Claim
12 words
The membrane of claim 4 wherein said plasticizing agent is n-octyl, n-decyl-trimellitate.
Claim 7
Dependent Claim
40 words
The membrane of claim 1 wherein said coating composition also includes minor amounts of a heat and light stabilizing agent, a UV resistance improving agent, a fire retardant, an opacifying pigment, and a fungicide, all for said polyvinyl chloride resin.
Claim 8
Dependent Claim
19 words
The membrane of claim 1 wherein said PVC resin is a homopolymer having an intrinsic viscosity of about 1.0-1.4.
Claim 9
Dependent Claim
21 words
The membrane of claim 7 wherein said PVC resin includes up to about 50% its weight of a blending resin therefor.
Claim 10
Dependent Claim
18 words
The membrane of claim 1 wherein one of said coated surfaces is embossed to a substantially matte condition.
Claim 11
Dependent Claim
24 words
The member of claim 1 wherein said base coating is present in an amount at least equal to the weight of said base fabric.
Claim 12
Dependent Claim
175 words
A process for producing a durable flexible membrane which comprises (a) saturating with a base coating composition a generally heavy and dense supporting and reinforcing reticular base fabric, said base fabric being formed of thick generally loose bundles each containing a large multiplicity of individual continuous filaments of a synthetic polymer characterized by generally high dimensional stability and resistance to heat and light, said multi-filament bundles being arranged in mechanically interengaged intersecting relation with interstices therein, the base fabric having a weight of substantially about 3-12 oz/yd 2 , to completely impregnate the interstices of said base fabric and form on its opposite sides continuous coatings of said composition, said composition consisting essentially of polyvinyl resin and as a plasticizing agent for said resin about 35-100% of its weight of a trimellitate ester which exhibits high resistance to separation from said resin and imparts to the coating high flexibilities at temperatures not higher than about -30° F.; and (b) heating the thus applied coating composition to a temperature sufficient to dry and cure the same.
Claim 13
Dependent Claim
175 words
A process for producing a durable flexible membrane which comprises (a) saturating with a base coating composition a generally heavy and dense supporting and reinforcing reticular base fabric, said base fabric being formed of thick generally loose bundles each containing a large multiplicity of individual continuous filaments of a synthetic polymer characterized by generally high dimensional stability and resistance to heat and light, said multi-filament bundles being arranged in mechanically interengaged intersecting relation with interstices therein, the base fabric having a weight of substantially about 3-12 oz/yd 2 , to completely impregnate the interstices of said base fabric and form on its opposite sides continuous coatings of said composition, said composition consisting essentially of polyvinyl resin and as a plasticizing agent for said resin about 35-100% of its weight of a trimellitate ester which exhibits high resistance to separation from said resin and imparts to the coating high flexibilities at temperatures not higher than about -30° F.; and (b) heating the thus applied coating composition to a temperature sufficient to dry and cure the same.
Claim 14
Dependent Claim
71 words
The process of claim 11 wherein the coating saturating said base fabric is dried to a generally gelled condition and thereafter at least one additional coating layer of said coating composition is applied to each of the opposite surfaces of said coated fabric and then heated at a sufficiently high temperature to fuse each subsequently applied coating to the underlying coating surface, and then drying and curing the final coated product.
Claim 15
Dependent Claim
49 words
The process of claim 12 wherein at least two additional layers of said coating composition are applied to each of the opposite sides of the originally coated fabric, the aggregate amount of the applied coatings being substantially equal to the aggregate weight of the base fabric and original coating.
Claim 16
Dependent Claim
31 words
The process of claim 11 wherein said trimellitate ester is a di- or trialkyl ester each alkyl group of which contains at least about 6 carbon atoms in a straight chain.
Claim 17
Dependent Claim
12 words
The process of claim 14 wherein said plasticizing agent is n-octyl, n-decyl-trimellitate.
Claim 18
Dependent Claim
40 words
The process of claim 11 wherein said coating composition also includes minor amounts of a heat and light stabilizing agent, a UV resistance improving agent, a fire retardant, an opacifying pigment, and a fungicide, all for said polyvinyl chloride resin.
Claim 19
Dependent Claim
19 words
The process of claim 11 wherein said PVC resin is a homopolymer having an intrinsic viscosity of about 1.0-1.4.
Claim 20
Dependent Claim
21 words
The process of claim 17 wherein said PVC resin includes up to about 50% its weight of a blending resin therefor.
Claim 21
Dependent Claim
35 words
The process of claim 12 wherein one such additional coating after being heated is subjected to a mechanical embossing step in order to impart to one side of the ultimate membrane a generally matte texture.
Claim 22
Dependent Claim
24 words
The process of claim 11 wherein said base coating is present in an amount at least equal to the weight of said base fabric.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-06-27 | 1986-12-27 | 1987-06-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-06-27 | 1990-12-27 | 1991-06-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-06-27 | 1994-12-27 | 1995-06-28 | $7700.00 | Window Closed / Lapsed |