DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
WATERPROOFING CUM INSULATION MEMBRANE FOR ROOFING SHEETS

APPLICANT:
PIDILITE INDUSTRIES LIMITED,
A company incorporated as per laws of India and having address as
Regent Chambers, 7th floor, Jamnalal Bajaj Marg, 208,
Nariman point,
Mumbai 400021

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application claims priority from Indian Provisional Patent Application 201621021576 filed on 23rd June 2016.

TECHNICAL FIELD
The present disclosure in general relates to the field of insulation and waterproofing of structures, and more particularly, to an insulating cum waterproofing membrane for waterproofing and insulating a roof and a method of application of the membrane.
BACKGROUND
[002] Roof is a very important part of a house or a hutment. The roof accounts up to 40 percent of the external surface area and is the first line of defence exposed to rains, cold waves, snow, sunrays, noise and heat. Roofs used in workshops, houses, temporary site offices, houses especially in slums and other structures are generally made up of metals, asbestos, cement, plastic sheets. These roofs are mostly adopted by dwellers because of the roof’s abundant availability, ease of installation (negligible installation time as compared to concrete roof slabs), reusability and ultimately due its low cost.
[003] However, the conventional roof tops may have disadvantages that cause problems during its use. One of the major problems faced by the roofed structure is lack of effective waterproofing and thermal insulation. The problem of waterproofing and thermal insulation may further lead the roof structure prone to dampness, thermal expansion, degradation due to weathering, exfoliation, leakages, punctures as well as pest and moss growth.
[004] In areas where the air is laden with corrosive salt, the metal roof's life span may be shortened. Similarly, polluted air in industrial areas may make tin topping less enduring than non-metallic roofing. Finally, metal roofs are noisy in the rain and are prone to corrosion which may later produce leakage problems in and near the roof.

[005] There is clearly a long-standing need for providing insulation and waterproofing to exposed roofing sheets structures and to have an improved resistance to deterioration from exposure to external elements comprising rains, cold waves, sunrays, noise and heat.
SUMMARY

[006] Before the present apparatuses along with components related thereto are described, it is to be understood that this disclosure is not limited to the methods, apparatuses, systems and their arrangement as described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure but may still be practicable within the scope of the invention. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present application. This summary is not intended to identify essential features of the subject matter nor it is intended for use in detecting or limiting the scope of the subject matter.

[007] In an embodiment, a waterproofing cum insulation membrane for waterproofing and insulating a roof is described. The membrane may be applied on an exposed substrate of the roof. The waterproofing cum insulation membrane may comprise an insulation material base layer for thermally insulating the exposed substrate. The insulation material base layer may be composed of materials comprising chemically inert, foamed, group of polymers. The insulation material base layer may have a maximum material density of 40 Kg/m3, a water absorption of less than 2%, an operating temperature up to 55° C and a thickness within a range of 1 mm to 10 mm. The waterproofing cum insulation membrane may further comprise a thin reflective layer applied on top of the insulation material base layer. The thin reflective layer may be enabled as a face layer, wherein the thin reflective layer further comprises weather resistant coatings or films employed to withstand weathering factors. The thin reflective layer may have a maximum material density of 40 Kg/m3, a water absorption of less than 2%, an operating temperature up to 55° C and a thickness within a range of 200 µm to 700 µm. The waterproofing cum insulation membrane may be applied on the substrate using a bonding agent (e.g. an adhesive) and a sealing means. The bonding agent may be employed for adhering the waterproofing cum insulation membrane to the substrate. Further, the sealing means may comprise a foil or film faced bituminous tape which may be employed for sealing pierced areas or cuts in the waterproofing cum insulation membrane.

[008] In an embodiment, a method of waterproofing and insulating a roof by covering an exposed surface of the roof with a waterproofing cum insulation membrane is described. The method may comprise cleaning a substrate layer of the exposed surface of the roof to remove unwanted external materials from the substrate layer. The method may further comprise piercing one or more areas of the waterproofing cum insulating membrane. The one or more areas being pierced are having protruded portions. The waterproofing cum insulating membrane may be formed of an insulation material base layer and a thin reflective layer applied on top of the insulation material base layer. The method may further comprise applying a bonding agent on the substrate and on bottom side of the insulation material base layer, wherein the bonding agent is further allowed to react for a predefined time. The method may further comprise pressing top side of the thin reflective layer by applying a mechanical pressure. The method may further comprise sealing the pierced areas of the waterproofing cum insulating membrane by using a sealing means. The method may further comprise allowing the arrangement undisturbed for a time up to 24 hours for final bonding.

BRIEF DESCRIPTION OF THE DRAWINGS

[009] The detailed description is described with reference to the accompanying Figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

[0010] Figure 1 illustrates a waterproofing and insulation membrane along with other components for roof insulation and waterproofing in accordance with an embodiment of the present disclosure.

[0011] Figure 2 illustrates a method of application of the waterproofing cum insulation membrane on curved roof in accordance with an embodiment of the present disclosure.

[0012] Figure 3 A and 3 B illustrates a method of application of bonding agent in accordance with an embodiment of the present disclosure.

[0013] Figure 4 illustrates a method of application of the waterproofing cum insulation membrane on flat roof in accordance with an embodiment of the present disclosure.

[0014] Figure 5 illustrates a method of application of bonding agent in accordance with an embodiment of the present disclosure.

[0015] Figure 6A and 6B illustrates a method of joining overlap of two-membranes, in accordance with an embodiment of the present disclosure.

[0016] Figure 7 illustrates a method of sealing of Bolts or Projections on the insulated Roof.
DETAILED DESCRIPTION

[0017] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.

[0018] The present disclosure in general is directed to apparatuses and method of protecting roofs from weathering factors. More particularly, the disclosure relates to a waterproofing cum insulation membrane for protecting an exposed roof and the method of application of the waterproofing cum insulation membrane on the exposed roof.

[0019] In an embodiment, the waterproofing cum insulation membrane along with other components may provide waterproofing aid to the roofs which may be directly exposed to atmosphere without any protective cover. The other components may further comprise a roof substrate, a bonding agent, sealing means, surface cleaning means and the like. The waterproofing cum insulation membrane may be a composite membrane comprising one or more layers for insulation, waterproofing and withstanding weather conditions.

[0020] In an embodiment, a method of application of the membrane for insulating and waterproofing the roof is described. The method of application may comprise techniques of applying the membrane on flat roofs or corrugated roofs. Further, the method may enable closing the gaps between the butt joints of the two membranes. The method may also comprise waterproofing methods for bolted joints or other fastening means which may be prone to water leakage.

[0021] One of the primary objective of the insulation cum waterproofing membrane is to insulate the hutments and houses from heat and cold as the roofs are very prone to conduct and transfer heat and cold through conduction and convection. The sun rays in the day may cause the roof to heat-up thereby resulting into an increase in the temperature of the room underneath the roof. In winter, cold waves may transfer the cold temperature from outside atmosphere to the room by conduction and convection. Thus, the insulation cum waterproof membrane may insulate and avoid unnecessary heat and cold transfer which causes comfortless life under the hutments or house. Another objective of the present insulation cum waterproof membrane is to protect the roof tops from the weathering factors including, but not limited to, the rains, snow, dust, reactive dust and materials.

[0022] Referring Figure 1, a waterproofing cum insulation membrane 103 for waterproofing and insulating a roofing sheet along with of other components is illustrated in accordance with an embodiment of the present disclosure. The other components may comprise one or more substrate layer 101 and a bonding agent layer 102. In an embodiment, the material of the substrate layer 101 may be dependent upon the material of the roof. The material of the roof may be one or more of asbestos, metal, plastic & fiber reinforced plastic, fiber, concrete / cement board, wood, and a framework made from any of the above material.

[0023] In an embodiment, the bonding agent layer 102 may be a bonding agent employed for adhesion purpose. The bonding agent may be a solvent based or water based synthetic material. The bonding agent may be a quick bonding agent. The bonding agent may be in the form of liquid which may be further applied as a thin film with the help of a spatula or brush. The bonding agent may be selected such that it may be applied in cases where there is a difficulty in application of pressure between the surfaces to be bonded. The techniques of applying bonding agent may comprise one or more of an edge application, a spot application, and a full surface application.

[0024] In an embodiment, the waterproofing cum insulation membrane 103 layer may be a composite membrane comprising of an insulating material base layer 104 (also referred hereinafter as a “nonmetallic side”) and a thin reflective layer 105 (also referred hereinafter as a “metallic side”). The functionality of the thin reflective layer 105 is to provide an insulation barrier which may prevent transfer of heat from either side. In on embodiment, in the winter season, the insulation material base layer 104 may not transfer heat from the room to the outside surrounding space over the roof thereby maintaining a constant temperature or heat in the room. In another embodiment, in the summer season, the same insulation layer 104 may prevent the transfer of heat at the roof surface from the surrounding space to the room space at the roof surface. The insulating material base layer 104 may be a waterproof layer thereby preventing water leakage from rooftops or water seepage in roof materials. The insulating material base layer 104 may comprise chemically inert foamed group of polymers selected from a group comprising treated or untreated polyethylene, chemically cross linked polyethylene, physically cross linked polyethylene, nitrile butadiene rubber, poly urethane, extruded polystyrene, expanded polystyrene, poly iso cyanurate (PIR) or combinations thereof. The desired properties of the insulating material base layer 104 may include:
• Thermal Insulation
• Non-Fibrous
• Chemically Inert
• Water Absorption < 2 %
• Water Vapor Permeability
• Operating Temperature up to 55°C
• Humidity: up to 100 %, Fold ability / Roll ability / Flexible,
• Thickness: 1 mm to 10 mm
• Noise Level reductions,
• Multiple Color Shades,
• Material Density: Maximum up to 40 Kg / m3,
• Easy for Cutting with either Home Scissors or Knife,
• Odorless

[0025] In an embodiment, the thin reflective layer 105 may comprise weather resistance materials selected from a group comprising Reinforced or Non Reinforced Aluminum Foil, Threaded / Non Threaded Aluminum Foil, Foil Scrim Kraft, Foil Kraft, Screen, Vinyl, Heavy Duty Foil, Polyethylene Facing, Polyvinyl alcohol based Coating, Acrylic / Acrylic Based Coating, Metallic Coatings, Polyethylene terephthalate Film, Adhesive Back PEEL off Paper, UV Barrier Film, Propylene Scrim Kraft, Propylene Scrim Kraft Polyester, Propylene Scrim Kraft Core Metalized Polyester or combinations thereof. The functionality of thin reflective layer 105 is to facilitate reflection of radiations to reflect heat energy, protection of roof and the insulating material base layer 104 from the effects of sun, wind, rain and snow. The thin reflective layer 105 may further avoid transmission of moisture from the surroundings to the insulation material base layer 104 due to the thin reflectivelayer’s property of resistance against the water absorption. The desired properties of the thin reflective layer 105 may include:
• Water Absorption < 2 %
• Operating Temperature: Up to 55°C,
• Weathering Resistant Coated Surfaces (Either Factory coated or Site Coated)
• UV Coated Surfaces (Either Factory coated or Site Coated)
• Multiple Color Shades
• Plain Faced or Contoured Faced or with Thread or Without Thread
• Thickness: 200 microns (desired thickness); Maximum up to 700 microns

[0026] In an exemplary embodiment, a comparative analysis of result sets obtained for testing heat reflectance efficiency of insulation of a cement sheet in presence or absence of waterproofing cum insulation membrane 103 on the cement sheet is illustrated in Table 1 below. The result set corresponding to each serial number provides result for a particular day with a timeline. For example, serial number 3 may define result set for a particular day with results corresponding to particular time at 12 pm and 3 pm.

Sr. No Time Without waterproofing cum insulation membrane With waterproofing cum insulation membrane
Upside Inside Upside Inside
1 12:00:00 PM 58 42.8 54.1 38.6
03:00:00 PM 57.6 41 53.2 37.5

2 12:00:00 PM 59.5 43.7 54.5 39.3
03:00:00 PM 57 42.3 53.4 37.5

3 12:00:00 PM 58.3 42.5 54.2 38
03:00:00 PM 57 42.8 53.4 37.5

4 12:00:00 PM 59.5 45 55.5 40
03:00:00 PM 58 43.4 54 38.5

5 12:00:00 PM 57.7 41.6 53.4 37
03:00:00 PM 56.5 40.4 52.3 35.5

6 12:00:00 PM 59.4 43.7 54.4 39
03:00:00 PM 57.2 41.9 53.8 37.5

7 12:00:00 PM 59.5 44.1 55.4 40
03:00:00 PM 58 42.9 54.3 38.5

8 12:00:00 PM 58 42 54 38
03:00:00 PM 57 42 53 37.5

9 12:00:00 PM 57.5 41 53.5 37
03:00:00 PM 56 40.2 52.1 35.5

10 12:00:00 PM 60.3 44.5 55.5 40.8
03:00:00 PM 59.2 43.1 54.2 39.6

11 12:00:00 PM 59.1 43 54.6 39
03:00:00 PM 57 42.9 53.2 37.5

12 12:00:00 PM 58.2 42.9 54.4 38
03:00:00 PM 57.5 41.7 53 37.5

13 12:00:00 PM 59.2 43 55.2 39
03:00:00 PM 57.8 41.3 53.6 37.5

14 12:00:00 PM 57.9 41.8 53.5 37.4
03:00:00 PM 56.4 40.2 52 35.5

15 12:00:00 PM 59.5 44.2 55.7 40.4
03:00:00 PM 58 43.1 54.5 38.5
Table 1

[0027] In another exemplary embodiment, comparative analysis of result sets obtained for testing percentage absorptivity of a cement sheet in presence or absence of waterproofing cum insulation membrane 103 on the cement sheet is illustrated in Table 2 below.

Sr. No. Test Without waterproofing cum insulation membrane With waterproofing cum insulation membrane
1 Water Absorption, % 24.6 Nil
Table 2
[0028] In an embodiment, the waterproofing and insulation of the rooftops or roofs using the insulation cum waterproofing membrane 103 may help the dwellers having houses with roofs made from metals, asbestos, cements, and the like. Such waterproofing and insulation of the rooftops or roofs may especially help the people living in slums and who cannot afford cement slab roofs. In addition, the present waterproofing and insulation of rooftops or roofs and its method of application may also be used in the following cases:
• Hutments and houses
• Slum dwellings
• Warehouses and factories
• Temporary site office in constructional areas
• Workshops
• Shops
• Other small and temporary structures

[0029] In an embodiment, referring figure 2, a method 200 of application of the membrane 103 on curved roof is illustrated in accordance with an embodiment of the present disclosure. At block 201, the roof surface (i.e. a substrate) and the waterproofing cum insulation membrane 103 are cleaned thoroughly and may be made free from unwanted particles including, but not limited to, dust, rust, oil and moisture.

[0030] At block 202, the bonding agent may be applied on the roof and the waterproofing cum insulation membrane 103 at the same edges from where the waterproofing cum insulation membrane 103 starts and ends as shown in Figure 3-A. Furthermore, the bonding agent may be applied at equal distances on the roof as shown in Figure 3-A.

[0031] At block 203, the bonding agent may be allowed to adhere and adjust to the arrangement of the roof and the waterproofing cum insulation membrane 103 for 10-15 minutes as shown in Figure 3-B and then the waterproofing cum insulation membrane 103 may be pressed with cloth for tight bonding.

[0032] At block 204, the arrangement may be allowed to settle and the final bonding may be completed within a time span of 24 hours.

[0033] In an embodiment, Referring Figure 4, a method of application of the waterproofing cum insulation membrane 103 on a flat roof is illustrated in accordance with an embodiment of the present disclosure. At block 401, the roof surface (i.e. the substrate) and the waterproofing cum insulation membrane 103 are cleaned thoroughly and may be made free from unwanted particles including, but not limited to, dust, rust, oil and moisture.

[0034] At block 402, the bonding agent may be stirred and applied on the roof and the underlying surface of the waterproofing cum insulation membrane 103 using a suitable brush. The bonding agent may be applied on the roof and the waterproofing cum insulation membrane 103 at the same edges from where the membrane 103 starts and ends as shown in figure 5. Furthermore, the bonding agent may be applied at equal distances on the roof.

[0035] At block 403, the bonding agent may be allowed to adhere and adjust to the arrangement of the roof and the waterproofing cum insulation membrane 103 for 10-15 minutes and then the waterproofing cum insulation membrane 103 may be pressed with cloth for tight bonding.

[0036] At block 404, the arrangement may be allowed to settle and the final bonding may be completed within a time span of 24 hours.

[0037] In an embodiment, referring to Figure 6, a method of joining the gap of two- waterproofing cum insulation membranes 103 is illustrated in accordance with an embodiment of the present disclosure. In scenarios of two sheets to be bonded, sideways, the two sheets will be overlapped on each other of around 4-6 inches area. At block 601, the two waterproofing cum insulation membranes 103 may be allowed to overlap with area overlap length of about 4-6 inches.

[0038] At block 602, the bonding agent may be applied on the metallic side of one membrane 103 and the non-metallic surface of the other membrane 103 on which the first membrane is to be overlapped may be as it is.

[0039] At block 603, the first waterproofing cum insulation membrane 103 may be pasted over other waterproofing cum insulation membrane 103 to be sealed and further pressure may be applied on the arrangement for the surfaces to get bonded to each other as shown in Figure 6-A and 6-B.

[0040] At block 604, the arrangement may be allowed to settle and final bonding process may be completed within 24 hours.

[0041] In an embodiment, in scenarios of Bolts or Projections on the Roof, the waterproofing cum insulation membrane 103 is force pierced vertically and the area around the pierced surface is sealed with an Aluminum Foil faced Bituminous tape as shown in Figure 7.

[0042] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
,CLAIMS:WE CLAIM:

1. A waterproofing and insulating membrane 103 for waterproofing and insulating a roof, wherein the waterproofing cum insulation membrane 103 is applied on an exposed substrate of the roof, the waterproofing cum insulation membrane 103 further comprising:
an insulation material base layer 104 employed for thermally insulating the exposed substrate, wherein the insulation material base layer 104 has a maximum material density of 40 Kg/m3, a water absorption of less than 2%, an operating temperature up to 55° C and a thickness within a range of 1 mm to 10 mm; and
a thin reflective layer 105 applied on top of the insulation material base layer 104, wherein the thin reflective layer 105 is employed for withstanding one or more weathering factors, and wherein the thin reflective layer 105 has a maximum material density of 40 Kg/m3, a water absorption of less than 2%, an operating temperature up to 55° C and a thickness within a range of 200µm to 700 µm.

2. The waterproofing and insulating membrane 103 of claim 1, wherein the insulation cum waterproofing membrane 103 is applied on the substrate using
a bonding agent employed for adhering the waterproofing cum insulation membrane 103 to the exposed substrate; and
a sealing means for sealing pierced areas or cuts in the waterproofing cum insulation membrane 103.

3. The waterproofing and insulating membrane 103 of claim 1, wherein the insulation material base layer 104 is composed of foamed materials comprising chemical inert group of polymers.

4. The waterproofing and insulating membrane 103 of claim 3, wherein the insulation material base layer 104 is composed of materials selected from group comprising a treated polyethylene, an untreated polyethylene, a chemically cross linked polyethylene, a physically cross linked polyethylene, a nitrile butadiene rubber, polyurethane, an extruded polystyrene, an expanded polystyrene, a polyisocyanurate or combinations thereof.

5. The waterproofing and insulating membrane 103 of claim 1, wherein the insulation material base layer 104 is flexible to comply with rollability and foldability.

6. The waterproofing and insulating membrane 103 of claim 1, wherein the thin reflective layer 105 is composed of materials selected from group comprising a reinforced or non-reinforced aluminium, a threaded or non-threaded aluminium, a propylene scrim kraft, a propylene scrim kraft polyester, a Propylene Scrim Kraft Core Metalized Polyester, a vinyl, a polyethylene, a polyethylene terephthalate (PET) or combinations thereof.

7. The waterproofing and insulating membrane 103 of claim 6, wherein the thin reflective layer 105 is adhered by applying a heavy or light mechanical pressure to the insulation material base layer 104 using glue either in hot or normal condition.

8. The waterproofing and insulating membrane 103 of claim 7, wherein the thin reflective layer 105 facilitates in reflection of radiations to reflect heat energy thereby protecting roof and the insulating material base layer 105 from the one or more weathering factors.

9. The waterproofing and insulating membrane 103 of claim 8, wherein the one or more weathering factors comprises one or more of rain, humidity, heat, snow, temperature cycling, oxygen, ozone, atmospheric pollutants, erosion, and ultraviolet radiation.

10. The waterproofing and insulating membrane 103 of claim 2, wherein the bonding agent is an adhesive, and wherein the adhesive is at least a solvent-based adhesive or a water-based synthetic rubber adhesive.

11. The waterproofing and insulating membrane 103 of claim 2, wherein the sealing means comprise at least an aluminium faced bituminous tape or adhesive strips with embossed metallic films.

12. The waterproofing and insulating membrane 103 of claim 3, wherein the materials selected for composing the insulation material base layer 104 has a porous structure, and wherein the porous structure enables the waterproofing cum insulation membrane 103 to absorb sound energy and reduce noise levels.

13. A method of waterproofing and insulating a roof by covering an exposed surface of the roof with a waterproofing cum insulation membrane 103, the method comprising:
cleaning a substrate layer 101 of the exposed surface of the roof to remove unwanted external materials from the substrate layer;
piercing one or more areas of the waterproofing cum insulating membrane 103, wherein the one or more areas being pierced are having protruded portions, wherein the waterproofing cum insulating membrane 103 is formed of an insulation material base layer 104 and a thin reflective layer;
applying a bonding agent on the substrate layer 101 and on bottom side of the insulation material base layer, wherein the bonding agent layer 102 is further allowed to react for a predefined time;
pressing the top side of the thin reflective layer 105 by applying a mechanical pressure; and
sealing the pierced areas of the waterproofing cum insulating membrane 103 by using a sealing means.

14. The method of claim 13, wherein the unwanted external material comprises one or more of Dust, Rust, Oil and Moisture.

15. The method of claim 13, wherein the insulation material base layer 104 has a maximum material density of 40 Kg/m3, a water absorption of less than 2%, an operating temperature up to 55° C and a thickness within a range of 1 mm to 10 mm.

16. The method of claim 13, wherein the thin reflective layer has a maximum material density of 40 Kg/m3, a water absorption of less than 2%, an operating temperature up to 55° C and a thickness within a range of 200µm to 700 µm.

17. The method of claim 13, wherein the bonding agent is applied by techniques selected from a group comprising an edge application, a spot application, a full surface application or a combination thereof.