Note: Descriptions are shown in the official language in which they were submitted.
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FASTENING WITH WIDE FASTENING MEMBRANE
Background of the Invention
As is known, membranes and other sheet and board materials are incorporated in
many different physical arrangements to protect against a wide range of
environmental
conditions. Examples include geotextiles to protect against water penetration
or erosion,
roof membranes and building wrap materials to protect against rain and wind,
and
membranes as well as sheet, haft and board materials that serve as vapor
barriers and
sound barriers. Other environmental products include tlrermal insulation for
buildings
and materials used for outdoor shelters, tarpaulins, pallet wrap and packaging
materials,
boat and machinery covers, plant covers and other covers for agricultural use,
and
temporary covers over garbage dumps. Generally, such products are cost-
sensitive
regarding manufacture and the labor required to apply or secure them in place.
Previous work in the area of wide fasteners include US Patent No. 6,035,498,
and
U.S. Patent No. 5,945,13 l, the entire contents of each of which are
incorporated herein
by reference as if entirely set forth.
Summary of the Invention
The invention features an environmental membrane which may advantageously
be of substantial dimensions in both length and width, comprised of a base
layer of
thermoplastic resin and, over at least one broad surface of the membrane, a
dispersion of
fastener elements, e.g., hook and loop fastener elements, that are available
for
engagement with complementary material for securing to the membrane.
An important preferred feature of many aspects of the invention is that the
base
layer of the membrane is in a permanently width-wise stretched condition
relative to its
machine direction (the machine direction being the direction of its continuous
production), in some cases the base layer being in a stretched condition in
both width-
wise and length-wise directions, and in some cases important cases being
biaxially-
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oriented. Preferred techniques for forming and stretching such base layer are
described in
U.S. patent applications USSN 08/789,637, filed January 27, 1997, now
abandoned in
favor ofUSSN 09/070,865, filed April 30, 1998, now U.S. Patent 6,035,498 and
USSN
09/518,853, filed March 3, 2000, all herein incorporated by reference in their
entirety. In
most cases the base layer has a thickness between about .001 inch and .015
inch,
preferably less than about .008 inch, while in some important instances the
thickness is
less than .005 inch, in certain cases even less than .003 inch.
Depending upon the particular type of membrane and fastening needs, the
fastener
elements are typically present at density of between about 50 to 2000 fastener
elements
per square inch, the fastener elements being distributed generally over the
entire broad
fastening aarface of the membrane, or over a margin or other region at which
attachment
i~ desired. In important cases, the density of the fastener elements is at
least 300 fastener
elerr~ents per square inch.
In certain broad aspects of the invention the fastener elements may be of any
form
provided in any manner, including post-forming or post-molding after
fabrication of the
base sheet, but in preferred cases the fastener elements are constructed for
hook and loop
fastening, and are formed integrally with the base sheet prior to stretching
the base sheet.
In certain preferred embodiments the fastener elements are of hook form, while
in
other cases the fasteners are of loop form, or are secured fibers that
fimetion as loops.
Broadly, loop-engageable hook elements may be of mushroom, palm tree or
single or multi-directioned hook form, and may be formed integrally with the
sheet, or
may be partially or fully post-formed after the base sheet is fabricated. In
certain
preferred embodiments the hooks are discretely molded elements, formed
simultaneously
with the base sheet. In particularly preferred embodiments of this aspect of
the invention,
hooks are of tapered profile, rising from a wide base at the base sheet to a
relatively
narrow loop-engageable crook.
Important embodiments of the above aspects of the invention include one or
more
of the following features. The fastener or hook elements are discretely molded
elements,
each preferably having a profile, in the direction of primary loading or in
certain cases, in
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the machine direction, that is like the base of a pyramid (pyramidal), rising
by taper from
a relatively wide profile base that is integral with the common base layer of
the
membrane to a narrower portion formed into a crook. The membrane has
dimensions of
at least two feet in both length and width and in important instances,
dimensions of at
least three feet or five feet or more in length, width or both. The
thermoplastic resin of
which the membrane and fastener elements is formed is selected f-om the group
consisting of polypropylene, polyethylene terephthalate, polyethylene and
nylon,
copolymers thereof, compatible mixtures thereof and compatible mixtures with
other
compatible materials such as selected rubber and rubber-like materials. In
important
instances the plastic resin includes a biocide or fungicide capable of
preventing growth of
biological material such as mold or fungus, or includes a U.V. absorber or
other additive
to protect the membrane from deterioration or includes an rose ct or vermin
repellant.
Also, in important instances the formed membrane is in a post-treated
condition, for
instance, after ~orm.ing, being rendered permeable or semi-permeable to air or
moisture
vapor in the case of building wrap or agricultural cover, or to water seepage,
in the case
of geotextiles of the type constructed for soil retention while capable of
passing water.
In other products, according to the invention, the base layer of the membrane
is
water impermeable, or impermeable to air, or retentive of solids, or
impenetrable or
repellant to vermin or so called "vectox", referring e.g. to rodents, birds
and insects that
may disturb the object being protected.
In cases where the fasteners are defined by loop material, it is preferable
that it
comprise a needled and stretched non-woven material formed, e.g., by the
techniques
described in U.S. patent application USSN 08/922,292, filed September 3, 1997
or
09/262,159, filed September 3, 1999 or 09/322,663, filed May 28, 1999, each of
which is
incorporated by reference. In some cases the non-woven material is pre-
stretched and
laminated to a pre-stretched plastic base layer; in other cases the materials
are laminated
prior to final stretching, the stretching of the base plastic layer serving to
help form hook-
engageable formations in the fibers of the non-woven material.
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According to one broad aspect of the invention, in a method of releasably
fastening objects together including (a) providing a first object with a
continuous hook
fastener membrane having a base of thermoplastic resin and an array of hook
fastener
elements formed contiguously with resin of one side of the base; and (b)
releasably
engaging complementary loop fastener elements of a second object to the
fastener
elements of the first object; there is an improvement (c) in which the base of
the fastener
membrane is a permanently stretched sheet of resin having a width of at least
61 cm (2
feet), a length greater than its width and a thickness of less than about 0.38
mm (0.015
inch).
Variations of this aspect of the invention can include one or more of the
following
features. The first object is a wall of a building, the second object is a
wall covering, the
method including securing the hook fastener membrane to the wall, and then
releasably
engaging the complementary loop fastener elements of the wall covering with
the
fastener elements of the hook fastener membrane. The wall of the building is
an exterior
wall and the wall covering is a siding material. The first object is a
subfloor of a
building, the second object is a fiaor covering, the method including securing
the hook
fastener membrane to the subfloor, and then releasably engaging the
complementary loop
fastener elements of the floor covering with the fastener elements of the hook
fastener
membrane. The first object is a roof of a building, the second object is a
roof covering,
the method including securing the hook fastener membrane to the roof, and then
releasably engaging the complementary loop fastener elements of the roof
covering with
the fastener elements of the hook fastener membrane. The roof covering is a
shingle.
The second object is a strap, the method including covering an item with the
hook
fastener membrane and then releasably securing the hook fastener membrane in
place by
releasably engaging the complementary loop fastener elements of the strap with
the
fastener elements"of the hook fastener membrane. The frst object is a sheet of
insulating
material, the second object is a building structure, the method including
securing the
hook fastener membrane of the insulating material to engageable loops disposed
on the
building structure. The hook fastener membrane of the first object is a vapor
barrier, the
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second object is a building structure, the method including securing the vapor
barrier to
the building structure by releasably engaging the complementary~loop fastener
elements
of the building structure with the fastener elements of the hook fastener
membrane.
Any of the variations of this aspect of the invention can also include one or
more
of the following features. The hook fastener membrane is permanently stretched
only in
a direction corresponding to its width. The thermoplastic resin of the hook
fastener
membrane is biaxially oriented. The base layer has a thickness less than about
0.13 mm
(0.005 inch). The hook fastener elements are discretely molded hook-shaped
projections.
The hook fastener membrane has a width of at least 1.5 meters (5 feet). The
fastener
elements are present at density of at least about 300 elements per square inch
generally
over the one side of the base of the hook fastener membrane. The thermoplastic
resin is
selected from the group consisting of polypropylene, polyethylene
terephthalate,
polyethylene and nylon, copolymers thereof, and compatible mixtures thereof
with each
other or with other compatible materials. The plastic resin includes a biocide
or
fungicide capable of preventing growth of biological material such as mold or
fungus, or
a U. V. absorbing additive or a fire repellant or other repellant or agent to
protect the
membrane or objects with which it is associated from deterioration or damage.
The hook
fastener membrane is permeable to a selected environmental fluid such as
water, vapor or
air.
In another broad aspect of the invention, a method of affixing in a protective
covering to a building exterior including (a) securing a hook fastener
membrane to the
building exterior, the hook fastener membrane including a base layer of
thermoplastic
resin and an array of hook fastener elements formed contiguously of the
thermoplastic
resin of the base, the hook fastener elements extending from a broad surface
of the base;
and (b) engaging complementary loop fastener elements of the protective
covering to the
fastener elements of the hook fastener membrane to releasably secure the
protective
covering to the building exterior; (c) is characterized in that the base layer
of the hook
fastener membrane is a permanently stretched sheet having a width of at least
61 cm (2
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feet), a length greater than its width and a thickness of less than about 0.38
mm (0.015
inch).
In another broad aspect of the invention a method of affixing a decorative
covering to a building interior including (a) securing a hook fastener
membrane to the
building interior, the hook fastener membrane including a base layer of
thermoplastic
resin and an array of hook fastener elements formed contiguously of the
thermoplastic
resin of the base, the hook fastener elements extending from a broad surface
of the base;
and (b) engaging complementary loop fastener elements of the decorative
covering to the
fastener elements of the hook fastener membrane to releasably secure the
decorative
covering to the building interior; (c) is characterized in that the base layer
of the fastener
membrane is a permanently width-wise stretched sheet having continuous length,
a width
of at least 61 cm (2 feet) and a thickness of between about 0.025 mm (0.001
inch) and
0.38 mm (0.015 inch).
In another broad aspect of the invention, a method of enclosing a space
including
(a) providing a hook fastener membrane including a base layer of thermoplastic
resin and
an array of hook fastener elements formed contiguously of the thermoplastic
resin of the
base, the hook fastener elements extending from a broad surface of the base;
(b)
providing a support structure including complementary loop fastener elements;
and (c)
securing the hook fastener membrane to the support structure by engaging the
hook
fastener elements with the loop fastener elements to thereby enclose the space
defined by
the support structure; (d) is characterized in that the base layer of the
fastener membrane
is a permanently stretched sheet having a width of at least 61 cm (2 feet), a
length greater
than its width and a thickness of less than about 0.3 8 mm (0.015 inch).
In another broad aspect of the invention, a method of securing a protective
cover
about an object including (a) placing the protective cover about the object,
the protective
cover including a hook fastener membrane including a base layer of
thermoplastic resin
and an array of hook fastener elements formed contiguously of the
thermoplastic resin of
the base, the hook fastener elements extending from a broad surface of the
base; and (b)
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securing the protective cover about the object with straps having
complementary loop
fastener elements for engagement with the hook fastener elements; (c) is
characterized in
that the base layer of the fastener membrane is a permanently stretched sheet
having a
width of at least 61 cm (2 feet), a length greater than its width and a
thickness of less than
about 0.38 mm (0.015 inch).
In another broad aspect of the invention, a method of removably securing a
flooring material to a subfloor including (a) permanently attaching an
intermediate
flooring layer to the subfloor, the intermediate flooring layer having a base
with a first
broad surface and an opposite, second broad surface, the first broad surface
having a
dispersion of fastener elements available for engagement, the second broad
surface being
disposed for attachment to the subfloor; (b) providing flooring material
having an
attachment surface and an opposite flooring surface, the attachment surface
bearing a
~a' '
complementarjl loop fastener material engageable by the fastener elements of
the
intermediate flooring layer; and (c) releasably engaging the complementary
fastener
material of the flooring material with the fastener elements to removably
secure the
flooring material to the subfloor; (d) is characterized in that the first
broad surface of the
base and the fastener elements are formed integrally of the same thermoplastic
resin the
first broad surface being a permanently stretched sheet having a width of at
least 61 cm (2
feet), a length greater than its width and a thickness of less than about 0.38
mm (0.015
inch).
Variations of this aspect of the invention can include one or more of the
following
features. The intermediate flooring layer further comprises a backing material
laminated
to the second surface of the membrane for attachment to the subfloor. The step
of
permanently attaching the intermediate flooring layer to the subfloor
comprises at least
one of stapling, nailing or screwing. The backing material comprises a
dimensionally
stable material such as pressboard or foamed or unfoamed plastic, such as
polyvinyl
chloride. The step of permanently attaching the intermediate flooring layer to
the
subfloor further comprises uncoiling the intermediate layer from a storage
roll and
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positioning the intermediate layer for attachment to the subfloor. The
flooring material
comprises tiles. The tiles have marginal portions shaped for interlocking with
adjacent
like tiles to aid tile alignment during installation and to avoid gapping
between adjacent
tiles during use. The composite flooring fastener is in rolled form. The
dimensionally
stable material has a plurality of parallel slits across its width to provide
flexibility and to
allow the composite flooring fastener to be rolled. The hook fastener elements
have
stems of tapered profile, tapering outwardly from a relatively wide base at
the base layer
to a smaller dimension and being of thermoplastic resin integral with the base
layer, the
hook fastener elements being exposed for engagement with complementary hook-
engageable material for securing to the membrane and being present at density
of
between about 50 to 5000 fastener elements per square inch generally over the
first broad
surface of the membrane.
According to another broad aspect of the invention, a water-impermeable roof
membrane is provided which is constructed and arranged to serve as an
important
structural element of roofing, having a lower surface that has properties
suitable for being
applied, directly or via an intervening layer, to a rough roof. In important
cases, a broad
surface of the membrane that bears hook or other fastener elements is adapted
to be
directed upwardly, for engagement with compatible fastener material associated
with
outer roof elements such as shingles, roof tiles or exterior decking that
overlie the roof
membrane. In important cases, the roof membrane is associated with
waterproofing
material at its lower surface, for instance the roof membrane constituting, or
being
provided with a layer of, waterproofing material or adhesive. In important
instances a
pressure-sensitive adhesive coating is provided upon the lower surface of the
base layer
of the membrane (with or without an intermediate layer), the membrane is
rolled upon
itself in a supply roll and the upper surface of the fastener elements of the
membrane is of
substance and configuration permitting releasable engagement with the pressure-
sensitive
adhesive, or a release layer is interposed.
In another aspect, the invention features a roof membrane comprising a base
layer
of thermoplastic resin, over at least one broad surface of which is disposed a
preferably
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wide dispersion of discrete hook elements, the hook elements being of
thermoplastic
resin integral with the base layer and available for engagement with hook-
engageable
material for securing to the membrane, the membrane having a lower surface
having
properties suitable for being applied to a roof, and the broad surface of the
roof
membrane being adapted to be directed upwardly, presenting upwardly-directed
hooks
for securing engagement with loop material associated with outer roof elements
such as
shingles, roof tiles or exterior decking. Preferably this base layer comprises
a
permanently width-wise stretched or a biaxially-stretched or oriented plastic
sheet. In
particular embodiments the resin includes a biocide or fungicide, and the
membrane has a
layer of waterproofing material or pressure-sensitive adhesive adhered to its
lower
surface.
According further to the invention, an installed roof is provided comprising a
roof
membrane of one of the forms described, installed upon a roof structure, and
outer roof
elements such ~s roof tiles, shingles or exterior decking having at least
under surface
portions comprised of compatible fastener material are engaged with fasteners
of the
upper surface of the roof membrane for securing the roof elements in place.
In another aspect of the invention, a roof is provided comprising a roof
structure
having a supporting surface carrying roof elements such as roof tiles,
shingles or exterior
decking, a fastener-bearing membrane is joined to either (1) the supporting
surface of the
roof or (2) at least under-surface portions of the roof elements, while a
compatible
fastener material having fastener elements engaged by the fastener elements of
the
membrane is joined to the other of the supporting surface or the undersurface
portions of
the roof elements.
According to another broad aspect of the invention, an exterior building wrap
material is provided comprising a fastener-bearing membrane which is permeable
to
moisture vapor but impermeable to wind, the membrane being sized to be wrapped
about
portions of a building and having fastener elements disposed to be engaged by
complementary fastener material to secure the wrap material to other
components of the
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building. In certain embodiments, the exterior building wrap material has
integral
fastener elements that are adapted to face inwardly of the building to engage
and be
supported by complementary fastener material previously fastened to the
building
stricture. In these and other important embodiments, the exterior building
wrap material
has fastener elements adapted to face outwardly of the building for engagement
by
complementary fastener strips for securing the wrap material to the building
or to
complementary fastener material on the inwardly facing surface of other
building
elements such as insulation or wall board or exterior siding material, the
building wrap
material supporting, at least in part, the other building elements.
In another aspect, the invention features an exterior building wrap membrane
comprising a base layer of thermoplastic resin, over at least one broad
surface of which is
disposed a preferably wide dispersion of discrete hook elements, the hook
elements being
of thermoplastic resin integral with the base layer and available for
engagement with
hook-engagea>~~e material for securing to the membrane, the membrane being
impermeable to wind, the hook elements being disposed to be engaged by loop
material
for fastening. Preferably, the base layer of this building wrap membrane
comprises a
permanently width-wise stretched plastic sheet, in certain cases being a
biaxially-
stretched or biaxially-oriented plastic sheet.
According further to the invention, a building at least partially wrapped by
an
exterior building wrap material is provided in which elements of the building
wrap
material dispersed over its interior surface lie against sheathing of the
building and define
therewith relatively isolated insulative air spaces, pockets or cells. In
these and other
cases, a building is provided which is wrapped by an exterior building wrap
material
according to the invention in which fastener elements dispersed over the
exterior surface
of the building wrap material face outwardly of the building and are engaged
by
complementary fasteners on fastener strips for securing the wrap material on
the building,
or by compatible fastener material associated with the inner surface of other
building
material such as siding or insulation or wall board which is at least
partially supported by
fastener elements of the membrane.
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In another aspect of the invention, a building is provided having its exterior
surface at least partially covered by a building wrap material, a membrane as
described
above either serving the role of being secured to the exterior surface of the
building with
fastener elements facing outwardly, or inwardly, or both, and a complementary
fastening
material having fastener elements engaged by the fastener elements of the
membrane
serves the complementary fastening role not served by the membrane.
According to another broad aspect of the invention, an insulation product is
provided in which a fastener-bearing membrane forms at least part of a surface
or outer
cover of a batt, or of a portion of a roll, or a sheet or board of building
insulation, which
may be thermal insulation or sound insulation, or both. The insulation is
disposed within
a cover formed by the membrane or laminated to the membrane, and the fastener
elements of the membrane are exposed on the exterior of the batt or portion of
the roll or
sheet or board ~f insulation in regions engageable with complementary
fastening material
disposed in stud, joist or rafter cavities or against building surfaces for
securing the batt
or portion of the roll or sheet or board of insulation in place.
In another aspect, the invention features a batt, roll, sheet or board of
building
insulation adapted for heat or sound insulation purposes, comprising
insulation disposed
within or against an outer cover, the outer cover comprising, at least in
part, a base layer
of thermoplastic resin and, disposed over at least one broad surface of the
membrane, a
wide dispersion of discrete hook elements. The hook elements are of
thermoplastic resin
integral with the base layer and are available for engagement with hook-
engageable
material for securing to the membrane. The hook elements of the membrane are
exposed
on the exterior of the batt, roll, sheet or board of insulation in regions
engageable with
loop material disposed in stud, joist or rafter cavities or against surfaces
for securing the
butt, portions of the roll, sheet or board of insulation in place. Preferably,
the base layer
comprises a permanently width-wise stretched plastic sheet, in certain cases
being a
biaxially-stretched or a biaxially-oriented plastic sheet.
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In another aspect of the invention, an insulated structure is provided
comprising a
batt, portion of a roll, sheet or board of building insulation as described
disposed between
wall studs, joists or rafters or against surfaces of a building structure and
engaged upon
areas of complementary fastener material secured to the studs, joists,
rafters, or surfaces
of other building materials.
In another aspect, an insulated structure is provided, comprising building
surfaces
or cavities defined by studs, joists, rafters or building material, with batts
or portions of
rolls, sheets or boards of building insulation disposed against the surfaces
or within the
cavities, a membrane as described either serving the role of a cover for the
building
insulation, or the role of providing fastener surfaces of the cavities or
surfaces, to which
the building insulation is secured, and a complementary fastener material
having fastener
elements engageable by the fastener elements of the membrane serves in the
other
fastening role not served by the membrane.
According to another broad aspect of the invention, a wallboard or panel is
provided, which may be e.g., gypsum board, wall board, blue board or
insulation board,
or a preformed wood or synthetic panel comprising a planar member to at least
one side
of which is joined a permanently width-wise stretched plastic sheet, in some
cases being
a biaxially-stretched or a biaxially-oriented plastic sheet having the
features as described,
preferably the broad surface of the membrane carrying the fastener elements
being
directed outwardly.
In another aspect, the invention features such a wallboard or panel comprising
a
planar member to at least one side of which is joined a membrane comprising a
base layer
of thermoplastic resin, and disposed over at least one broad surface of the
membrane is a
dispersion of discrete hook elements, the hook elements having a tapered
profile, tapering
from a relatively wide base at the base layer to relatively narrow crook
portions, and
being of thermoplastic resin integral with the base layer and available for
engagement
with hook-engageable material for securing to the membrane, the broad surface
of the
membrane which carries the hook elements being directed outwardly. In
preferred
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embodiments, the base layer comprises a permanently width-wise stretched
plastic sheet,
in certain cases being a biaxially-stretched or a biaxially-oriented plastic
sheet.
Another embodiment is a wall board or building panel having a planar surface
to
at least one side of which is joined a membrane comprising a base layer of
thermoplastic
resin, over at least one broad surface of the membrane there being a
dispersion of hook-
engageable loops, the loops being directed outwardly, available for engagement
with
hook for securing to the membrane. In preferred embodiments, the base layer
comprises
a permanently width-wise stretched or a biaxially-stretched or biaxially-
oriented plastic
sheet. In preferred embodiments, the loop material is provided by a needled
nonwoven of
staple fibers which subsequent to needling, has been substantially stretched
and bonded
from the back in that state.
According to another broad aspect of the invention, a wall or ceiling covering
is
provided in the~form of wallpaper, fabric, paneling or insulation having a
decorative side
and an oppositely directed side, and to the latter side is joined a
permanently width-wise
stretched plastic sheet, in certain cases the sheet being a biaxially-
stretched or a biaxially-
oriented plastic sheet, the fastener elements of the sheet being directed
inwardly for
attachment to a complementary fastener surface disposed on a supporting wall
or ceiling
structure.
In another aspect, the invention features a wall covering comprising
wallpaper,
fabric, paneling or insulation having a decorative side and an oppositely
directed side to
the latter of which is joined a membrane comprising a base layer of
thermoplastic resin.
Disposed over at least one broad surface of this membrane is a dispersion of
discrete
hook elements, the hook elements having a tapered profile from a relatively
wide base at
the base layer and being of thermoplastic resin integral with the hale layer
and available
for engagement with hook-engageable material for securing to the membrane, the
hook
elements of the membrane being directed inwardly for attachment to a loop
surface
disposed on a supporting wall. In preferred embodiments the base layer
comprises
biaxially-oriented plastic sheet.
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In another aspect of the invention, a wall is provided which is defined by an
extended supporting surface carrying a wall covering, and a permanently width-
wise
stretched or a biaxially-oriented plastic membrane is joined to either (1) the
supporting
surface of the wall or (2) the wall covering, while a compatible fastener
material engaged
by the fastener elements of the membrane is joined to the other of the
supporting surface
or wall covering. In particular embodiments of this aspect of the invention,
the
supporting surface comprises wallboard or a building panel, and complementary
membranes having features according to the invention are on both of its sides.
Another embodiment of the invention is a wall defined by an extended
supporting
surface carrying a wall covering. There is a membrane having a base layer of
thermoplastic resin, over at least one broad surface of which is a dispersion
of discrete
hook elements of profile that tapers outwardly from a relatively wide base at
the base
layer, being of th~°rmoplastic resin integral with the base layer,
these hook elements being
available for engagement with hook-engageable material for securing to the
membrane.
The membrane is joined to either (1) the supporting surface of the wall or (2)
the wall
covering, while a loop material capable of being engaged by the hook elements
of the
membrane is joined to the other of the supporting surface or wall covering. In
preferred
embodiments the base layer comprises a permanently width-wise stretched
plastic sheet,
in certain cases it being a biaxially-stretched or a biaxially-oriented
plastic sheet.
Another embodiment of the invention comprises an installed ceiling defined by
an
extended supporting surface carrying a ceiling covering comprising wall paper,
fabric,
ceiling tile or ceiling sound or thermal insulation, and a permanently width-
wise stretched
membrane, in certain cases being a biaxially-stretched or a biaxially-oriented
plastic
membrane, is joined to either (1) the supporting surface of the ceiling or (2)
the ceiling
covering, while a compatible fastener material capable of being engaged by the
fastener
elements of the membrane is joined to the other of the supporting surface or
ceiling
covering. Complementary membranes having features according to the invention
may be
respectively on both of these surfaces.
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WO 01/81771 PCT/USO1/13752
Another embodiment is an installed ceiling defined by an extended supporting
surface carrying a ceiling covering comprising wall paper, fabric, ceiling
tile or ceiling
sound or thermal insulation. There is a membrane having a base layer of
thermoplastic
resin, over at least one broad surface of which is a dispersion of discrete
hook elements of
profile that tapers outwardly from a relatively wide base at the base layer
and being of
thermoplastic resin integral with the base layer, and available for engagement
with hook-
engageable material for securing to the membrane. The membrane is joined to
either (1)
the supporting surface of the ceiling or (2) the ceiling covering, while a
loop material
capable of being engaged by the hook elements of the membrane is joined to the
other of
said supporting surface or ceiling covering. In preferred embodiments the base
layer
comprises a permanently width-wise stretched plastic sheet, in certain cases
being a
biaxially-stretched o:- a biaxially-oriented plastic sheet.
Accord,~ng to another broad aspect of the invention, a floor membrane is
provided
comprising a permanently width-wise stretched plastic membrane, in certain
cases a
biaxially-stretched or biaxially-oriented plastic membrane, the floor membrane
having a
lower surface that has physical properties suitable for being joined to a
subfloor (either
directly or via an intervening layer), the broad surface of the floor membrane
being
adapted to be directed upwardly, presenting upwardly directed fastener
elements for
engagement with complementary fastener elements associated with a finished
floor
material such as ceramic, vinyl or cork tile, wood flooring (in particular,
hardwood
flooring strips) or carpeting.
In preferred embodiments a water-proofing material or pressure-sensitive
adhesive layer is joined to or forms part of the membrane.
Another embodiment of the invention is a floor membrane comprising a base
layer of thermoplastic resin, over at least one broad surface of which is a
dispersion of
discrete hook elements having a profile that tapers outwardly from a
relatively wide base
at the base layer and being of thermoplastic resin integral with the base
layer, the hook
elements being available for engagement with hook-engageable material for
securing to
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the membrane. The membrane has a lower surface having physical properties
suitable for
being joined to a subfloor, and the broad surface of the membrane is directed
upwardly,
presenting upwardly directed hook elements for engagement with loops
associated with a
finished floor material such as ceramic, vinyl or cork tile, wood flooring (in
particular,
hardwood flooring strips) or carpeting. In preferred embodiments the base
layer
comprises a permanently width-wise stretched plastic sheet, in certain cases
being a
biaxially-stretched or a biaxially-oriented plastic sheet.
In another embodiment, a floor comprises a subfloor, at least one layer
ofwater
proofing material or adhesive substance is adhered to the subfloor, and a
membrane is
secured or laminated to the at least one layer of waterproofing material or
adhesive
substance, the membrane comprising a permanently width-wise stretched plastic
sheet, in
certain cases a biaxially-stretched or a biaxially-oriented plastic sheet
having its broad
surface carrying fastener elements directed upwardly, and the flooring
material having
compatible fast~ner~material on its under surface engaged with fastener
elements of the
broad surface. In certain preferred embodiments, the flooring material
respectively
comprises ceramic tile, a composition tile such as vinyl or cork tile, a wood
flooring such
as oak flooring strips, or carpeting. In certain cases the floor is that of a
tent, a sales
booth, a commercial display, a TV or movie set, a theatrical stage, or other
temporary or
low-cost structure.
Another embodiment of the invention is an installed floor comprising a
subfloor,
preferably at least one layer of waterproofing material or adhesive substance
adhered to
the subfloor, a membrane secured or laminated to the at least one layer of
waterproofing
material or adhesive substance, or directly to the subfloor the membrane
comprising a
base layer of thermoplastic resin, over at least one broad surface of which is
a dispersion
of discrete hook elements that have a profile that tapers from a relatively
wide base at the
base layer and being of thermoplastic resin integral with the base layer, the
hook
elements being available for engagement with hook-engageable material for
securing to
the membrane. The membrane has its broad surface carrying the hook elements
directed
upwardly, and the flooring material has hook-engageable loop material on its
under
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surface engaged with the hook elements of the broad surface. In preferred
embodiments
the base layer comprises a permanently width-wise stretched sheet, in certain
cases being
a biaxially-stretched or a biaxially-oriented plastic sheet.
According to another broad aspect of the invention, a protective membrane
bearing a dispersion of fasteners, preferably one component of a hook and loop
fastening,
is constructed and arranged to form a flexible exterior cover impermeable to
water, such
as rain or ground water. In certain embodiments, a flexible exterior cover
impermeable
to water comprises a base layer of thermoplastic resin, over at least one
broad surface of
which is a dispersion of discrete hook elements of thermoplastic resin that
are integral
with the base layer and available for engagement with hock-engageable material
for
securing to the membrane. Preferably, the base layer comprises a
permanentlyvidth-
wise stretched ,elastic sheet, in certain cases being a biaxially-stretched or
a biaxially-
oriented plastid, sheet. In certain embodiments, the exterior cover is in the
form of a
ground cover, typically black or dark green, adapted to resist deterioration
when exposed
to sun light. In certain cases, the exterior cover is constructed in the form
of a
greenhouse cover or a roof material, the cover or roof material being at least
translucent,
capable of transmitting a substantial fraction of incident light. In certain
cases a
greenhouse or other roof comprises one or more roof supports having fastener
material on
the supports and two portions of membrane as described. One of the portions of
membrane comprises an exterior layer, having its fastener elements directed
inwardly,
and engaged upon an outer portion of the fastener material on the one or more
roof
supports, while the other of the portions or membrane comprises an interior
layer, having
its fastener elements directed outwardly and engaged upon an inner portion of
fastener
material on the one or more roof supports.
Another embodiment of the invention is a greenhouse or other roof comprising
one or more roof supports having loop material on its exterior and two
portions of
membrane each comprising a base layer of thermoplastic resin over at least one
broad
surface of which is a dispersion of discrete hook elements of thermoplastic
resin integral
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WO 01/81771 PCT/USO1/13752
with the base layer and available for engagement with hook-engageable material
for
securing to the membrane. One of the portions of membrane comprises an
exterior layer,
having its hook elements directed inwardly, and engaged upon an outer portion
of loop
material on one or more of the roof supports. The other of the portions of
membrane
comprises an interior layer, having its hook elements directed outwardly and
engaged
upon an inner portion of loop material on one or more of the roof supports. In
preferred
embodiments the base layer comprises a permanently width-wise stretched or a
biaxially-
oriented plastic sheet.
Another embodiment of a fastener-bearing protective membrane is a flexible
exterior cover impermeable to water which is sized, constructed and arranged
as a
tarpaulin, and which is associated with straps comprised of compatible
fastener material,
the tarpaulin or the straps at least being stretchy.
Other embodiments of flexible exterior covers having fastener features as
described include: a~ protective cover for shrubs, trees, plant material,
pallet loads or
packages such a~ gifts to protect the object covered during shipping or
storage, the
protective cover sized and shaped to be wrapped about the object and secured
by
compatible fastener material engaged upon the fastener elements of the cover;
a boat or
vehicle cover comprising the exterior cover sized and shaped to be wrapped
about the
boat or vehicle and secured by loop material engaged upon the fastener
elements of the
cover; the exterior cover sized and constructed as an agricultural cover to
cover
agricultural objects such as the ground around growing plants, protective
cover for
tobacco plants, hay bales, straw stacks, ensilage, farm machinery, or earth; a
geotextile
comprising an exterior cover of the type described, sized and constructed for
use in
diverting or containing water or preventing erosion or surrounding drain pipe
as in a so-
called French drain installation; or a swimming pool cover sized and
constructed to cover
a swimming pool.
Another embodiment of the invention comprises an upholstered object of
furniture or the like, an inner cover comprising a membrane having fastener
features as
described, secured over the object with the fastener elements directed
outwardly, and an
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outer material (such as finished upholstery fabric) having compatible
fasteners (such as
loops of the fabric) directed inwardly and engaged with fastener elements of
the
membrane generally over the exterior of the object.
Another embodiment of the invention is a moving pad or blanket comprising a
broad layer of padding or filling and a cover on the padding or filling, the
cover
comprising a membrane having fastener elements as described, the fastener
elements
being exposed to be engaged by compatible fastener elements for securing it in
place. In
preferred embodiments, the moving pad or blanket includes straps of compatible
fastener
material capable of engaging the fastener elements of the moving pad or
blanket, with at
least the membrane or the straps being stretchy.
Another embodiment is a moving pad or blanket comprising a broad layer of
padding or filling and, on the padding or failing, a cover membrane
cor.~prising a base
layer of thermoplastic resin, over at least one broad surface of the membrane
there being
a dispersion of~iiscrete hock elements of thermoplastic resin integral with
the base layer
and available for engagement with hook engageable material for securing to the
membrane, the hook elements of the membrane being generally distributed over
the
exterior of the object. Preferably the base layer comprises a permanently
width-wise
stretched sheet, in certain cases being a biaxially-stretched or a biaxially-
oriented plastic
sheet and preferably the moving pad or blanket is associated with straps of
loop material
capable of engaging the hook elements of the moving pad or blanket, preferably
at least
the membrane or the loops being stretchy.
In another embodiment, an insulation blanket comprises a blanket of insulating
material covered on at least one side with the protective membrane comprising
a base
layer of thermoplastic resin, over at least one broad surface of which is a
dispersion of
discrete hook elements of thermoplastic resin that are integral with the base
layer and
available for engagement with hook-engageable material for securing to the
membrane.
Preferably, the base layer comprises a permanently width-wise stretched
plastic sheet, in
certain cases being a biaxially-stretched or a biaxially-oriented plastic
sheet.
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According to another aspect of the invention, there is provided a method of
making a protective membrane product of selected properties as described,
which
comprises continuously forming a layer of plastic with integral molded
projections by use
of a rotating mold roll, thereafter heating and stretching the plastic layer
at least width-
wise to substantially increase the width of the membrane and introduce
molecular
orientation, and thereafter sizing, cutting and arranging the membrane so that
it is
constructed and arranged to serve as the protective membrane product, the
steps of
molding and stretching being cooperatively related to provide the selected
properties. In
some cases, after forming the membrane, it may be permanently stretched both
width-
wise and length-wise. This stretching action may produce a desired permanent
biaxial
orientation of the molecules of certain resins, under certain conditions of
treatment. The
method of making a membi ane can employ any of the processes disclosed in the
following specification or in the prior U.S. patent applications and patents
which have
been incorporated by reference.
Another aspect of the invention is the method of making a protective or
barrier
membrane product of selected properties comprising continuously forming a
layer of
plastic of selected ream with integral projections by use of a rotating mold
roll having
mold cavities ofpreselected dimensions, thereafter heating and stretching the
layer at
least width-wise, substantially increasing the width of the membrane, and
thereafter
sizing, cutting and arranging the membrane into the form of the selected
product, the
steps of forming and stretching being cooperatively related to provide the
selected
properties.
Preferred embodiments have one or more of the following features.
The method includes the step of treating the formed layer of plastic to render
it
permeable to a selected degree.
The method includes punching the formed sheet, preferably the punching being
produced by electrical discharge punching, laser punching, pin roll punching,
needling or
treatment of the sheet with a beam of energetic electrons.
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Other features and advantages will be apparent from the following detailed
description, claims, and attached drawings, and from the disclosures of our
prior U.S.
patent applications and patents which have been incorporated by reference
above.
Brief Description of the Drawing-s
Figs. 1 and 2 illustrate a method of fabricating a membrane for products of
the
invention.
Fig. 3 illustrates a roofing material membrane.
Fig. 3A is a cross-sectional view taken along line 3 A-3 A of Fig. 3.
Fig. 3B is a cross-sectional view similar to that of Fig. 3A illustrating an
alternate
arrangement of the roofing membrane of Fig. 3
Fig. 4 is a cross-sectional view of roofing shingles secured to the roofing
membrane of Fig. 3 that has been affixed to a roof, while Fig. 4A is a
magnified view of a
portion of Fig... .
Fig. 5 is a cross-sectional view of one embodiment of a roofing shingle.
Fig. a illustrates a membrane used to secure flooring materials.
Figs. 7, 7A and 7B diagrammatically illustrate methods of fabricating
composite
flooring fasteners incorporating flooring fastener membranes similar to that
of Fig. 6.
Fig. 8 illustrates an alternate flooring fastener member used to secure
flooring
materials.
Fig. 9 illustrates the flooring fastener member of Fig. 8 being used to secure
flooring material to a subfloor.
Fig. 10 illustrates a flooring fastener composite in an uninstalled, roll
form.
Fig. 11 illustrates the flooring fastener composite of Fig. 10 in an unrolled
state
capable of receiving a mating flooring material.
Fig. 12 illustrates an alternative embodiment of the flooring fastener
composite of
Fig. 10.
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Fig. I3 illustrates an apparatus and method for forming the flooring fastener
composites of Figs. 10 and 12.
Fig. 14 illustrates a membrane used as a protective exterior structural wrap.
Fig. 15 and 15A are cross-sectional views of stages of securing structural
members to a hook-presenting membrane affixed to a structure.
Fig. 16 illustrates a membrane used to install insulation in a structure.
Fig. 17 is a cross-sectional view of a membrane used for wallboards and
insulation while Fig. 17A is a magnified view of a portion of Fig. 17.
Fig. 18 illustrates a hook-bearing membrane used to secure ceiling members.
Fig. 19 illustrates a membrane used to secure wall members.
Fig. 20 illustrates a membrane used as a protective tarpaulin.
Fig. 2l. illustrates a membrane used in constructing a shelter.
Fig. 22 is a cross-sectional view of one embodiment of a support member for a
shelter having .the membrane ofFig. 21.
Like reference symbolism the various drawings indicate like elements.
Detailed Description of Embodiments
As previously indicated, protective membranes of substantial dimensions in
both
length and width carrying a field of fasteners, are formed by stretching a
thermoplastic
sheet, preferably after the hooks are molded integrally with the sheet or
other fastener
elements are joined to the sheet.
A protective membrane with integral hooks and having substantial dimensions in
length and width, typically at least about two feet to about five feet, and
often much more
is formed generally according to the method disclosed in pending applications
USSN
08/789,637, filed January 27, 1997, USSN 09/070,865, filed April 30, 1998, now
U.S.
Patent 6,035,498 and USSN 09/518,853, filed March 3, 2000, which are
incorporated
herein in their entirety. To briefly summarize, referring to Figs. 1 and 2,
the membrane is
preferably manufactured by pulling sheet-form molten resin from the die lips
of an
extruder, into a nip formed by two counter-rotating calendar rolls. At least
one of them is
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WO 01/81771 PCT/USO1/13752
a mold roll, which defines over it surface afield of tiny mold cavities e.g.,
of hook form
suitable for hook and loop fastening. At the nip an extended field of hook-
form fastener
elements is molded on at least one surface of the thin membrane that is formed
by the
calendar rolls. As shown in Fig. 2, the sheet is then stretched width-wise up
to 4 to 5
times its original width to produce a membrane having biaxially-oriented
polymeric
molecules, which provides strength to the stretched membrane. With suitable
choice of
resin and thickness for the particular application, the substantial width of
the stretched
membrane that is achievable by the process allows it to be constructed to
serve as a
protective barrier in the numerous novel uses arid structures described here.
The membrane includes a base layer typically comprising a biaxially-oriented
plastic sheet of thermoplastic resin. Depending upon the application, the
resin used may
be homo polypropylene, homo polyethylene terephthalate, homo nylon, and homo
polyethylene, and copolymers and/or mechanical mixtures of these polymers. The
r esin
is selected specially to achieve appropriate properties for the novel product.
For
example, for ceiling members (as described below), a polyethylene
terephthalate resin
may be preferred because of its hardness and the strong hooks it forms,
capable of
supporting vertical weight. For extremely wide membranes as used where seams
are
undesirable, a polypropylene resin is preferred because it is easy to stretch
to great width.
i3y choice of suitable resin and thickness, the thermoplastic resin base layer
of the
stretched membrane can act as a protective barrier that is air-impermeable and
water-
impermeable, or with properties specially tailored to the application.
Disposed over at least one broad surface of the membrane is a dispersion of
fastener elements, in many cases, preferably discrete hooks for hook and loop
fastening.
As used herein, "hooks" broadly includes any hooking element, e.g., hooks with
crooks,
hooks of mushroom or palm tree shape, etc., that can engage with a compatible
loop
material, for example, a nonwoven, needled-loop material or a knitted or woven
loop
material. The hooks are typically present at a density of between about 25 to
2,000 hooks
per square inch over at least one surface of the protective membrane,
depending on the
application for the membrane. The hooks, made of thermoplastic resin,
preferably
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WO 01/81771 PCT/USO1/13752
formed integral with the base layer, are available to engage with hook-
engageable
material, e.g., a layer of loops, for securing the material to the membrane.
Thus, not only
can the membrane of the invention serve as a fastener, but because of its
substantial
dimensions, the membrane can also serve as a protective membrane, for example,
against
water, air, pests, etc., with the added advantage of being able to secure hook-
engageable
materials thereon.
Other examples of techniques for forming loop engageable elements are those
described in European patent application EP 0 852 918 A2 and subsequent
corresponding
patent publications, and in WO/00/00053, text and drawings of which are hereby
incorporated by reference.
Where the protective membrane carries loop fastener elements, it is
advantageous
that a film of thermoplastic resin be formed by the well-known blown film
method, to
produce a biaxially oriented film, which is then laminated to a needled non-
woven which
has been extensively stretched, preferably biaxially, e.g., as described in
USSN
08/922,292, filed September 3, 1997, USSN 09/262,159, filed March 3, 1999 and
USSN
09/322,663, filed May 28, 1994, all incorporated by reference in their
entirety. In other
cases a preformed loop material can be introduced wivh molten resin into the
nip of a pair
of calendar rolls in which a plastic membrane is formed on the back of the
loop fabric or
loop perform, the composite then being stretched width-wise.
Generally, applications of the membrane of the invention are directed to broad
area covers. The membrane is typically placed on an object with the hooks or
other
fasteners facing outward, away from the object. In some applications,
additional
material, such as shingles, having a mating layer, e.g., loop layer, secured
to the
membrane by engaging the loop layer to the hooks of the membrane. Depending on
the
application, the membrane is readily treated with an adhesive to secure the
membrane to
the object and to provide an added waterproofing layer. Additionally, the
membrane or
mating layer can include a biocide or fungicide, to prevent growth of
biological material
such as mold and fungus, or an ultraviolet absorbing agent to protect the
membrane from
deterioration. Specific novel products include but are not limited to, roofing
material,
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WO 01/81771 PCT/USO1/13752
flooring material, building wrap, insulation wrappings, ceiling material,
wallpaper,
tarpaulin, geotextiles, green house roofs, upholstered objects, moving pads,
blankets and
insulation blankets.
While only certain methods of fabricating the protective membrane have been
disclosed above, it should be recognized that, within the broader aspects of
the inventions
protective membrane disclosed can be fabricated by other methods. For example,
these
methods can include extruding a sheet of molten plastic into a roller nip or a
narrow gap
formed by a nozzle shaped about a roller and subsequently stretching the sheet
in both
width and length directions after forming (with or without molecular
orientation). Also
the well-known "cut and stretch" method can be employed in which parallel ribs
of hook
profile, formed integrally with a'oase plastic layer, are repeatedly cut
transversely without
cutting the base layer :~nd the base layer is then stretched in the axial
direction of the ribs
to separate the hook segments, as well as width-wise to provide the needed
length. and
width for the rr~mbrane or sheet. Moreover, while the methods of application
for the
membrane describe below suggest placing the membrane on the object to be
protected, it
should be noted that, for appropriate applications, the placement of the
membrane and the
loop layer can generally be reversed, with the layer having loops disposed on
the object
to be protected.
Whereas one aspect of the invention is, in general, the concept of providing a
novel pi otective membrane bearing a field of fasteners, produced by the
techniques
disclosed, other aspects of the invention concerns specific protective
membranes and as
well as the systems of employing them and specific combinations of the
membranes with
other elements that form novel end products and usages.
Generally, a protective membrane and the object to be secured to the hooks of
the
membrane can experience three types of forces: tension, peel, and shear.
According to
the invention, these properties are selected for a given membrane product, to
accomplish
the novel function for which that product is uniquely designed. For instance,
ceiling
coverings have hook fasteners that are constructed to be especially strong
under tensile
forces to support the attached ceiling tiles or other coverings. The hooks of
roof
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WO 01/81771 PCT/USO1/13752
membranes are constructed to be especially resistant to peeling forces, to
securely attach
roofing shingles. A wall-mounted membrane for supporting tiles on vertical
walls have
fastener elements especially constructed to be strong in shear, to support the
tiles
vertically.
Generally, the size of the cooperating loops depends on how much force the
object will experience; and the size of the hooks is related to the size of
the loops. For
example, ceilings tiles may be secured with #24 hooks available from Velcro
USA, Inc.,
Manchester, New Hampshire, while wall tiles may be secured with #3905 hooks
available from Velcro USA, Inc.
Other special properties for specific membranes according to the invention
depend upon their novel application, including thickness, width-wise stiffness
and
strength, color, and other properties relevant to the novel application. For
example, i~ the
membrane is used as a roofing material, the membrane may be black to better
accommodate trhe effects of sunlight while a membrane specially constructed
for a green
house roof is typically translucent to pass the sun's rays.
Novel Roofing Membrane
Referring to Fig. 3, the membrane 100 comprises a protective roofing material
for
a structure 110, such as a house or a building. The base sheet of membrane 100
is
constructed to be an air-impermeable and water-impermeable protective barrier.
It
carries a uniform field of molded hooks over its upper surface, and, in the
particular
embodiment shown, an edge band of loop material along at least one edge of the
downwardly facing side. This fastener hook-bearing underlayment is adapted for
attaching roofing shingles. Roof membrane 100 is typically provided on a
supply roll
105 and is rolled onto the roof 101, for example, like tarpaper, to cover the
entire roof
with the hooks facing up and away from the roof 101.
The membrane 100 can be affixed to the roof 101 by a number of advantageous
methods, or combinations thereof. In one example, the membrane 100 is pre-
coated on
its bottom surface with a pressure sensitive adhesive such as a rubber-based
adhesive 113
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WO 01/81771 PCT/USO1/13752
that is compatible with the material of the roof 101, for bonding to the roof.
Such
adhesives can be chosen such that the membrane can be easily released when
rolled upon
itself, or a release sheet may be interposed between successive layers of
membrane in the
roll. Additionally, the adhesive can be selected to serve as an added
waterproofing
barrier, further protecting the structure from the effects of rain and wind. A
sealing
arrangement can be provided by applying material having a layer of loops on
one surface
and a layer of hooks on another surface, such as provided by strips 107 ofFig.
3A.
The membrane can also be mechanically affixed to the roof, for example, by
staples and nails, 111, Fig. 3B. The seams between adjacent layers of membrane
100 can
further be sealed with over-lying sealing strips 107 that protect against
leakage at the
locations of perforation points of the staples or nails.
Preferably the overlying sealing stripy 107 have an under-surface of hook-
engageable loops, and an upper surface ef hooks, e.g., of density
corresponding to that of
the membrane.~100.~ The under surface can include an adhesive sealant material
which is
penetrated by the hooks and forms a water-tight seal between the base layer of
the
membrane 100 and the base layer of strip 107, to complete the water-tight
seal.
A self joining strip 107 can be fabricated, for example, by laminating a layer
of
loops to the back of a preformed hook membrane. In another embodiment,
material is
introduced for forming the loops, e.g., loose fibers, with the molten resin
feed that enters
a forming nip, either by use of free fibers or a stretchy loop-defining
fabric. Using either
of these methods, after forming the base layer sheet with hooks on the
opposite side at the
forming nip, the composite can be stretched to a very thin base thickness
since the layer
of loop-forming fibers can stretch along with the base layer.
In a low cost method of producing a roof membrane, only outer edge margin of
the back of a membrane is provided with loops, as shown in Fig. 3. The central
region of
the back of the sheet can carry, for example, a sealant or a tar paper layer,
optionally
impregnated with fire retardant or sealant substance to provide low-cost
thickness and
strength. The loop margin 109 of the sheet is disposed at the region of
overlap of
successive courses of the membrane, with the loops facing down to engage the
hooks on
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WO 01/81771 PCT/USO1/13752
the lower membrane course. The resultant membrane has hooks facing up
throughout its
entire extent to receive roofing elements, such as a shingles, tiles, and
decking, as
described below.
The membrane 100 of Fig. 3 can advantageously be covered with roofing
elements such as a shingle 103, as shown in Fig. 4. Each shingle 103 has a
specially
provided under-surface comprising a layer of loops 104. Each shingle 103 is
attached to
the roof 101 by engaging the loops 104 of the shingle to the hooks of the
membrane 100
(and/or the strip 107) on roof 101.
In one preferred embodiment, as shown in Fig. 5, shingle 103 further includes
a
band of hooks 140 disposed on the lower margin of the top surface of the
shingle to be
engaged by the layer of loops on the lower margin of the under-surface of the
overlapping roof ng element, see Fig. 4A. The band of hooks 140, typically I
or 2 inches
wide, thus better secui es the exposed edge of the shingle 103. In this way
the shingles
103 positioned~on the roof 101, are secured on their under-surface to the
membrane 100
and to shingles they overlap, and in turn assist in securing the further
shingles that
overlap them.
In cerair~ preferred embodiments of this aspect of the invention, fungicide or
biocide is incorporated in the substance of the membrane or the loop. material
to protect
the roof 101 from organic growth.
Novel Flooring
A flooring underlayment, in the form of a protective membrane is especially
fabricated to secure finished flooring materials. The membrane carries hooks
on its upper
surface which are constructed to be strong in peel and shear, and the
stretching of the
membrane during its manufacture solves the problem of achieving a wide field
of molded
hooks in an economically practical manner in regard to cost of materials and
the labor of
placement. Flooring materials that may be secured to this novel underlayment
include,
but are not limited to, ceramic, vinyl and cork tiles; parquet blocks;
hardwood flooring;
and carpeting. In Fig. 6, a floor 201 is shown being completely covered with
membrane
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200, which has a uniform field of hooks 202 facing upwardly, away from the
subfloor
which is for example of concrete 206 or support beams 208. (Figure 6 is
suggestive of the
hooks but does not show their uniform dispersion over the entire floor which
is the
presently preferred embodiment). The membrane 200 covering the floor offers
the
advantages of sound insulation by providing a layer of air space defined by
the hooks and
loops and a uniform cushioning effect provided by the dispersion of upstanding
hooks,
e.g. avoiding the hard sensation and sounds that poured concrete subfloors 206
typically
provide, see left side of Fig. 6. The membrane 200 can be coated with a
permanent,
strong adhesive to bond to the concrete 206 or plyv~iood 208 subfloor
material. The
membrane 200 can serve to waterproof the floor and may include in its base
layer
additives that prevent fungi, mold, and other organic growth. In one example,
the
membrane 200 (or a laminated backing described below) includes a flame
retardant
additive to resist the spread of flames across or through a flcaor employing
such a flooring
membrane 200. Where temporary installation is desired, the membrane 200 can be
coated with a temporary adhesive such that the flooring material and the
membrane 200
can be easily removed or it may be temporarily nailed or stapled. This feature
is useful
for, e.g., a carpeted floor of a tent, a sales booth, a commercial display, a
television or
movie set, or a theatrical stage. The finished flooring materials 203, e.g.,
tiles or
hardwood flooring are provided with a layer of hook-engageable loops 204 on
their
under-surface to engage with the hooks 202 of the membrane 200. When the
flooring
material is for instance a tile, the joints between the tiles can be grouted
directly on the
membrane 200.
In an alternative embodiment, the width-wise stretched and extended membrane
underlayment provides an upwardly directed loop surface, and hooks are
provided on the
under surfaces of the finished floor elements.
Also, as described in previously incorporated U.S. Patent 6,035,498, an added
material can be laminated to the stretched membrane on the side opposite the
fastener
members. After forming and stretching the member, e.g., as described above
with
reference to Fig. 1, the added material is laminated to the membrane. As
illustrated in
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Figs. 7, 7A and 7B, the stretched membrane is heated by heating unit 216 in
such a
manner that the fastener members are not appreciably deformed. With the back
surface
219 of the web of the membrane in a heat-softened condition, added material
220 from a
source spool 222, or rigid added material 220' in flat stock form (Fig. 7A) is
brought into
contact with the back surface of web 200 as the web is passed over a
laminating roller
224 before being spooled on takeup roller 226 or accumulated as a stack 226'
of flat
sheets in the case of rigid added material 220'(Fig. 7B) for later use. In the
embodiment
of Fig. 7, the web 200, under a degree of tension, is trained about an arc of
the laminating
roll, which thereby exerts pressure between the web back surface 219 and the
added
material. As it cools and solidifies, web back surface 219 permanently adheres
to added
material 220 supplied from the laminating roller, to form a two-sided product
228 that
may be many feet wide, with fastener members on one side and the added
material on the
oth~°r side.
For novel flooring underlayments, the added material can be, for example, a
foam
material which advantageously provides sound absorption dualities to the
installed floor
and also offers increased friction between the subfioor and the flooring
membrane. In
another example, rigid added material 220' (Figs. 7A and 7B) is pressboard to
provide
support to the membrane and to provide a stable surface for improved adhesion
of the
membrane to the subfloor. In yet another example, rigid backing material 220'
is a
foamed rigid plastic sheet, such as a foamed polyvinyl chloride sheet sold
commercially
under the tradename "Sintra"TM.
In one embodiment, illustrated in Figs. 8 and 9, a composite flooring
underlayment 300 is provided having a stretched membrane 302 with exposed
fastener
elements 304 and a laminated pressboard backing 306. Composite flooring 300 is
cut to
a desired size and shape and secured to subfloor 308, e.g., of wood, by for
example,
staples 310. Tiles 312, e.g., of vinyl material, having fastener element-
engageable loop
material 314 on one broad surface opposite appearance surface 315 are provided
for
securement to composite flooring underlayment 300. Each tile 312 has a male
key
feature 316 present along two marginal edges (one such edge shown) and a
female
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feature 318 present along two other marginal edges (one such edge shown). With
loop
material 314 facing fastener elements 304 of secured composite flooring 300,
tile 312 is
pressed against composite flooring 3700. Fastener elements 304 engage loop
material
314 to secure tile 312 in the desired position. A like tile 312' having like
features 316
and 318 is then pressed downward (in the direction of arrow d of Fig. 9),
interconnected
with secured tile 312, and secured to composite underlayment 300.
Interconnection
features 316 and 318 provide stability to maintain tight joints and secure
adjacent tiles to
prevent gaps from forming. The tile installation process is repeated until
installation of
the flooring is complete.
Each tile is thus releasably secured to the flooring underlayer and the
flooring
system provides easy installation, easy flooring material, e.g., tile removal
and
replacement, easy repair, e.g., removal and replacement of individual damaged
tiles. Tile
composite flooring underlayer also provides a flooring moisture barrier.
As desa~ibed above, flooring fastener membranes of substantial dimensions in
both length and width carrying a field of fasteners, are formed by stretching
a
thermoplastic sheet, preferably after the hooks are molded integrally with the
sheet or
other fastener elements are joined to the sheet.
In one example, as illustrated in Figs. 10 and 11 composite flooring fastener
400
having flexible support layer 409 disposed between rigid backing 406 and
stretched
fastener membrane 402 is provided in roll-form for ease of storage, shipping
and use.
Rigid backing layer 406 is of a dimensionally stable, rigid material, e.g.,
masonite, glass
filled plastic, wood, filled or unfilled and foamed or unfoamed thermoplastic
or thermoset
sheet, composites of wood and virgin or recycled plastic or other materials
with similar
properties.
Rigid backing layer 406 is slit laterally across its width, the slit extending
through
the rigid backing layer 406, but not extending through flexible support layer
909, which
remains intact. The slitting of backing layer 406 allows composite flooring
fastener 400
to be rolled in superposed form, as shown, despite the relative rigidity of
backing layer
406, i.e., as composite flooring fastener material 400 is rolled, indvidiual
slats 407
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separate along the outer circumference of each rolled layer, while remaining
attached in
their relative positions to flexible support layer 409 along the inner
circumference of each
rolled layer. The separation of individual slats along an outer roll layer
circumference
allows rigid layer 406 to flexibly coil.
When composite fastener material 400 is unrolled, e.g., during installation to
be
fastened to a subfloor, spacing between adjacent individual Mats 407 is
eliminated. In the
unrolled, e.g., installed condition, individual rigid slats 407 abut each
other thereby
supporting each other against any lateral loading that might be experienced by
flooring
composite 400. Together, individual slats 407 in their unrolled, abutting
arrangement
provide support for the stretched fastener membrane 402, any flooring
material,
decorative or otherwise, attached to membrane 402, and any loads experienced
by the
flooring material to prevent undesirable buckling or wrinkling of the
installed flooring
material. Additionally, if composite fastener material 400 is attached, e.g.,
by staples,
adhesives, nails, or otherwise, to an associated underfloor, or if composite
material
constitutes a wall to wall flooring underlayment whereby abutting ~,valls
offer lateral
support to the system, the rigid backing layer 406 in conjunction with the
engagement of
fastener members 403 with mating fastener material on an underside of the
exposed
flooring acts to prevent any movement of the exposed flooring relative to the
underfloor.
Alternatively, fastener membrane 402 is an unstretched fastener product having
fastener elements extending from a base. In this embodiment the base width,
length, and
thickness dimensions, and the spacing between adj acent fastener elements
remain
significantly unaltered after initial forming of the fastener product shape.
In either case, intermediate flexible support layer 409 is of, e.g., polyvinyl
chloride, polypropylene, foamed polypropylene, polypropylene compound,
thermoplastic
elastomers, olefinic thermoplastic elastomers, thermoplastic polyurethane
elastomers, or
other materials, in a foamed or unfoamed condition. Layer 409 is provided to
support
stretched fastener membrane 402 (or an unstretched fastener membrane) on one
broad
surface and to adhere slit rigid backing material 406 on its opposite broad
surface.
Flexible support layer 409 can also provide additional desirable properties
such as sound
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barrier, antibacterial/fungal treatment, moisture barrier, or flame retarding
characteristics,
depending on the material used and additives introduced or coatings applied.
Alternatively, as illustrated in Figure 12, composite flooring fastener 400'
has slit
rigid backing material 406 bonded directly to stretched fastener membrane 402,
i.e.,
intermediate flexible support layer 409 is eliminated. In this embodiment,
fastener
membrane 402 is of appropriate thickness after stretching to provide the
necessary
support to slit rigid backing material 406 in its flexed, rolled condition
(Fig. 10) and in its
unrolled, installed condition (Fig. 6) to support flooring an attached
flooring material. As
described above with reference to flexible support layer 409, the properties
of fastener
membrane 402 can be modified as desired by appropriate choice of material,
additives,
coatings or any combination of chess constituents.
Tri-layered h:ninate 400 can be produced by a modification of the fastener
membrane forming and backing layer laminating processes described above with
reference to Figs. l, 2, 7 and 7A. As illustrated in Fig. 13, necessary
modifications to the
process to form composite fastener 400 include lamination of intermediate
flexible
support layer 409 to the non-fastener member bearing surface 430 of stretched
fastener
membrane 402. Attachment of rigid backing layer 406 to the exposed surface 432
of
support layer 409 is achieved, for example, by an adhesive applied (e.g., by
supplying
adhesive to be wiped on by roller 433) or lamination by heat applied (e.g., by
supplying
heat through roller 433) to the undersurface of support layer 409 prior to
bringing
exposed surface 432 into contact with rigid backing layer 406. Rigid backing
layer 406 is
subsequently slit, at slitting station 434, the slitting being accomplished
without severing
support layer 409, to form individual, flex-providing slats 407. In another
embodiment,
intermediate support layer 409 and rigid backing layer are joined, e.g., by an
adhesive or
by lamination, prior to attachment to fastener membrane 402. The pre joined
rigid
backing layer can be slit prior to or after attachment of membrane 402 to
intermediate
layer 409. In any of these embodiments, the tri-layered product 400 with slit
rigid
backing 406 is then wound into roll form as illustrated at 436.
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Alternatively, composite floor fastener 400', described above with reference
to
Fig. 12, is produced by eliminating the intermediate flexible support layer
409 and
attaching rigid backing layer 406 directly to non-fastener member bearing
surface 430 of
membrane 402.
Composite flooring fastener 400 (or 400') can be wound into roll-forrr~ for
subseql~ent storage, shipping, and installation. Installation of flooring
fastener 400 is
achieved by cutting portions of adequate size and shape to fit a particular
subfloor to be
covered. Each such portion is then attached by, e.g., staples, glue, or other
joining
means, to the subfloor. In this manner, multiple pieces of flooring fastener
400 can be
cut to shape, positioned, and adhered in an adjacent manner to completely
cover a
su~floor. A temporary cover, e.g., a plastic film or sheet, can be placed over
the exposed
fastener elements of flooring fastener 400 during installation to avoid
unwanted
engagement of the fastener elements with, e.g., clothing of an installation
workEr or other
work materials~that may come into contact with the fastener elements. When the
flooring
fastener 400 is adhered in its desired location, the protective cover is
removed and a
flooring material having an attachment surface with fastener element
engageable backing
material is removeably attached to the exposed fastener element bearing
surface of
secured flooring fastener 400.
Novel Building Wrap Material
A protective exterior structural wrap is shown in Fig. 14, 15 and 15A. Similar
to
conventional building wrap material, such as DuPont's Tyvek~, the membrane is
used to
wrap a structure as a vapor-permeable, wind and water-impermeable protective
barrier.
In this case, the base layer of the membrane, after formation, is subjected
e.g., to
electrical discharge punching or other pore-forming techniques that render the
base layer
vapor-permeable, such as laser punching or drilling, pin roll punching,
needling or
treatment of the sheet with a beam of energetic electrons or ions.
A membrane placed upon a structure may have hooks facing only away from the
structure, with the membrane being secured mechanically to the structure,
e.g., by
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WO 01/81771 PCT/USO1/13752
stapling, or by a waterproof adhesive. However, in the case shown in Fig. 14,
the
membrane 700 has loop-engageable hooks 702 formed on both sides of the base
layer.
For securing the membrane to the building 701, the inwardly facing hooks
engage with
strategically located loop strips 705 that have previously been secured to the
building.
Outer (or inner) wall defining members '703, such as clapboard siding,
sheathing, or
wallboard is attached to the outwardly directed hooks 702 of the membrane by
hook-
engageable loops 704 disposed on the wall-defining members 703. As with the
roofing
elements, at overlapping joints of the wall-defining members, a marginal band
of hooks
may be provided to engage with the layer of loops on the structural member
that overlaps
it.
In other embodiments, fields of hooks can be disposed on the wall-defining
members, arid the building wrap membrane may provide a field of loops with
which the
hooks of the wall-defining members engage.
A further feature of the invention is that the engaged hooks and loops define
cells
of isolated air space between the base layer of the membrane and the
structural or wall
members, to provide thermal or sound insulation.
Further Novel Insulation Applications
Referring now to Figs. 16, 17 and 17A, a membrane 900 is used to install
insulation into a structure while providing an added air or moisture barrier,
as previously
generally described. In one embodiment, a batt or a portion of insulation 901
is wrapped
with a membrane 900 that has hooks facing outwardly from the insulation. The
insulation may be a glass fiber batt, cellulose insulation, particulate foam
or a foam
board. The membrane is secured, e.g., laminated or glued, onto the exterior of
the
portion of insulation 901 or formed as a sealed envelope containing the
insulation. The
portion of insulation 901 is positioned into a cavity defined by structural
support
members 908 such as studs, joists, rafters, etc, that carry loop material 910.
The
insulation is secured by engaging the hooks 902 of the membrane wrapper with
loop
material 910 disposed on the support members. Alternatively, a membrane
carrying loop
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material can be provided on the outer wrap of the insulation, and portions of
a hook-
bearing membrane can be disposed on the support members.
The effect is to removably install the insulation in a tight-fitting manner in
a
cavity, thus to prevent leaks of cold air at the boundaries, etc.
In the embodiment of Fig. 9 a further membrane 900' has loops 904 on its inner
side which engage with hooks earned by the insulation or by structural
members.
Membrane 900' also has hooks 902 on its outside. A wall board 903 or other
wall
covering having loop material 904 on its inside surface is placed against the
membrane
with the matching hooks and loops engaged to hold the wall board or other
covering in
position.
Novel Ceiling Installation
As shown in Fig. 18 a membrane 1100 is fabricated to secure ceiling members
1103 such as tines, sound-insulating bricks, cellular material, fixtures, or
paneling. As
shown, the ceiling 1101 is covered with membrane 1100 that has uniform
dispersion of
loop-engageable hooks 1102 facing downwardly, away from the ceiling. The
membrane
can be secured to the ceiling, for example, by using staples or adhesives, or
by hook and
loop engagement between complementary hooks and loops provided on the upper
surface
of the membrane and ceiling support members, respectively, or vice versa with
respect to
the location of the hooks and loops.
In Fig. 18, the finished ceiling members 1103, having a layer of loop material
1104 disposed on their upper surfaces, are attached to the membrane 1100 by
engaging
the hooks 1102 of the membrane with the loops of the finished ceiling members.
Since
the weight of the ceiling members is entirely borne by the hooks and loops,
the hook and
loop material preferably has high creep resistance in the tensile direction to
secure the
ceiling members to the ceiling. In preferred cases the base layer of the
membrane is in
permanently stretched condition, as has been described.
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Novel Wall Coverings
As shown in Fig. l9, a stretched and preferably biaxially oriented membrane
1200
is used to secure wall treatments 1203 such as wallpaper (shown in Fig.),
fabric or
paneling. The wall treatment materials are secured to a wall 1201 carrying
membrane
1200 with the hooks 1202 of the membrane facing out from the wall. The plastic
membrane offers moisture proofing, an air movement barrier, and added sojznd
and
thermal insulation. The wall treatment material shown has a layer of loop
material 1204
disposed on its inner surface. The loop material itself can be chosen to
provide additional
properties such as heat insulation, sound insulation, soft feel, etc, while
the dead air cells
defined by the engaged hooks and loops add to the insulating as well as a
texturizing and
softening effect. The membrane may be affixed to the wall with staples or an
adhesive,
for example. The adhesive can be temporary or permanent, depending upon the
application, and the adhesive can be selected to provide additional
waierproofing, organic
growth control'; vermin and insect protection, etc. While the wall treatment
members are
shown secured to the wall by engaging the loops to the hooks, in an
alternative
embodiment, the loop material can be carried on a stretched membrane disposed
on the
wall, and a hook-bearing membrane can be provided on the inside surface of the
wall .
covering. In other embodiments a membrane may carry hook or loop fastener
elements
on both surfaces, one side serving to secure the membrane to the wall and the
other side
serving to secure the wall covering. The systems described may be used
advantageously
to mount temporary wall treatments, e.g., for theatrical stages or sales
booths and
displays, and may be used to mount fabrics carrying advertisements or
decoration that
can readily be changed. For further features useful for this product see U.S.
Application
U.S.S.N. 09/322,663 which is incorporated by reference in its entirety.
Novel Outdoor Covers
As shown in Fig. 20, a membrane 1300 is constructed for use as a protective
tarpaulin, which is air-impermeable and water-impermeable, and which provides
the
added benefit of easy securement. The membrane can also be treated with or
incorporate
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a biocide or fungicide to resist organic growth. By virtue of the stretching
techniques
described, the membrane can be manufactured to a size large enough to cover
large
objects 1301 to be protected. Such objects include, e.g., shrubs, trees, plant
materials,
boats, vehicles, agricultural objects such as hay bales, straw stacks,
ensilage, farm
machinery, earth or plants and swimming pools. These objects are typically
covered with
the membrane 1300 having the hocks 1302 facing toward the exterior, and strips
1303 of
loop material 1304 are suitably engaged with the hooks and supporting
structure to secure
the tarpaulin to itself and/or around a pallet or the protected object, as
shown in the
figure. In an alternative embodiment the location of the hooks and loops is
reversed.
Novel Shelters, Greenhouses and Tents
Referring to Figs. 21 and 22, membranes 1500, 1500' are constructed for use as
a
shelter such as a greenhouse or a tent. The membrane is provided with
sufficient '
thickness and strength to span substantial distances between supports and to
resist the
forces of storm-force winds and rains. It is constructed as a protective
barrier that is air-
impermeable and water-impermeable, though it may be provided with pores, as
described
above, to enable transmission of water vapor. As shown in Fig. 22, in one
embodiment,
the shelter is formed of a frame 1503 made of a rigid material such as metal
piping, PVC
piping, etc. Disposed on the exterior of the frame elements is loop material
1504. For
example, the loop material is wrapped around rigid pipes. Inner and outer
layers of
membrane 1 S00 and 1500' are provided, typically of transparent membrane,
which are
supported by the frame. The outer membrane 1500 has its hooks facing toward
the
interior, to engage with the loop material of the pipe supports to define the
shelter, e.g., a
greenhouse. Additionally, the shelter can include the additional layer 1500'
of membrane
to provide better thermal insulation. In this case the hooks of the membrane
1500'
directed upwardly engage loops on the supporting pipes.
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Novel Geotextiles
In another embodiment, a membrane is constructed as a geotextile or
geomembrane. Typically, these are large sheets that are used to retain soil
against
erosion, to confine water flows, etc. In the prior art, typically adjacent
sheets are joined
together by gluing, welding or stitching. By constructing a geotextile or
geomembrane
according to the invention, strips of loop material engage areas of hooks of
adjacent
membrane sheets to hold them in place, or overlapping margins of adjacent
membrane
sheets are provided with appropriately placed sections or bands of hook and
loop that are
mated to join overlapping sheets together. Additionally, adhesive strips
covering the
joints may be used to keep the joints water-impermeable, or hook and loop
strips 507
including sealant, such as disclosed in Figs. 4A and 4B may be used to seal
the joints.
Other preferred features and configurations of fastener material disclosed in
our
earlier U.S. patent applications, incorporated by reference above, are useful
in the
construction o~.the various products that ha~~ a been described, and provide
further novel
features.
What is claimed is:
39
