Carrier membrane, coated membrane composite, and method

A method of making a pliable reinforcement carrier membrane for use in a coated membrane composite, comprising:

• forming and processing a flexible, non-woven, fibrous mat comprising entangled polymeric fibers in a manner such that a first major surface of the fibrous mat has portions of a portion of the polymeric fibers of the non-woven fibrous mat protruding therefrom in extent and in sufficient amounts that the protruding polymeric fiber portions give the first major surface of the non-woven fibrous mat a fuzzy characteristic to facilitate adhesion of a coating material to the first major surface of the fibrous mat and a second major surface of the fibrous mat has a generally smooth, non-fuzzy surface;
• the fibrous mat having a length, a width, and a thickness;
• the first major surface and the second major surface of the fibrous mat each being defined by the length and the width of the fibrous mat;
• introducing a hydrophobic binder into the fibrous mat for bonding together the polymeric fibers of the fibrous mat;
• curing the binder of the fibrous mat to bond together the polymeric fibers of the fibrous mat;
• and
• curing the hydrophobic binder such that the hydrophobic binder remains somewhat tacky and is present on the second major surface of the fibrous mat in an amount sufficient to give the second major surface of the fibrous mat a tackiness to increase surface friction of the second major surface of the fibrous mat.

A pliable waterproof composite, comprising:

• a pliable non-woven fibrous mat;
• the fibrous mat comprising entangled polymeric fibers and a hydrophobic binder that bonds the polymeric fibers together;
• the fibrous mat having a length, a width, and a thickness;
• the fibrous mat having a first major surface and a second major surface that are each defined by the length and the width of the fibrous mat;
• the first major surface of the fibrous mat having portions of a portion of the polymeric fibers of the non-woven fibrous mat protruding therefrom in extent and in sufficient amounts to give the first major surface of the non-woven fibrous mat a fuzzy characteristic to facilitate adhesion of a coating material to the first major surface of the fibrous mat;
• and the second major surface of the fibrous mat being a generally smooth, non-fuzzy surface;
• wherein the hydrophobic binder is present on the second major surface of the fibrous mat;
• and the hydrophobic binder on the second major surface of the fibrous mat retains an innate tackiness and is present in an amount sufficient to increase surface friction of the second major surface of the fibrous mat;
• and
• a filled asphalt, modified bitumen, or non-asphaltic polymeric coating overlying, substantially coextensive with, and adhered to the first major surface of the fibrous mat to provide a barrier against liquid water transmission through and form a bottom major surface of the pliable waterproof composite.

A method of making a pliable waterproof composite, comprising:

• providing a pliable non-woven fibrous mat;
• the fibrous mat comprising entangled polymeric fibers and a hydrophobic binder that bonds the polymeric fibers together;
• the fibrous mat having a length, a width, and a thickness;
• the fibrous mat having a first major surface and a second major surface that are each defined by the length and the width of the fibrous mat;
• the first major surface of the fibrous mat having portions of a portion of the polymeric fibers of the non-woven fibrous mat protruding therefrom in extent and in sufficient amounts to give the first major surface of the non-woven fibrous mat a fuzzy characteristic to facilitate adhesion of a coating material to the first major surface of the fibrous mat;
• and the second major surface of the fibrous mat being a generally smooth, non-fuzzy surface;
• and
• coating the first major surface of the fibrous mat with a filled asphalt, modified bitumen, or non-asphaltic polymeric coating that overlies, is substantially coextensive with, and adhered to the first major surface of the fibrous mat to provide a barrier against liquid water transmission and form a bottom major surface of the pliable waterproof composite;
• wherein the hydrophobic binder is present on the second major surface of the fibrous mat;
• and the hydrophobic binder on the second major surface of the fibrous mat retains an innate tackiness and is present in an amount sufficient to increase surface friction of the second major surface of the fibrous mat.

A method of making a pliable waterproof roofing composite, comprising:

• forming a reinforcement carrier membrane by forming and processing a flexible, non-woven, fibrous mat comprising entangled polymeric fibers in a manner such that a first major surface of the fibrous mat has portions of a portion of the polymeric fibers of the non-woven fibrous mat protruding therefrom in extent and in sufficient amounts to give the first major surface of the non-woven fibrous mat a fuzzy characteristic to facilitate adhesion of a coating material to the first major surface of the fibrous mat and a second major surface of the fibrous mat has a generally smooth, non-fuzzy surface;
• the fibrous mat having a length, a width, and a thickness;
• the first major surface and the second major surface of the fibrous mat each being defined by the length and the width of the fibrous mat;
• introducing a hydrophobic binder into the fibrous mat for bonding together the polymeric fibers of the fibrous mat;
• and curing the binder of the fibrous mat to bond the polymeric fibers of the fibrous mat together;
• and
• coating the first major surface of the fibrous mat with a filled asphalt, modified bitumen, or non-asphaltic polymeric coating that overlies, is substantially coextensive with, and adhered to the first major surface of the fibrous mat to provide a barrier against liquid water transmission and form a bottom major surface of the pliable waterproof roofing composite;
• wherein the hydrophobic binder is present on the second major surface of the fibrous mat;
• and the hydrophobic binder on the second major surface of the fibrous mat retains an innate tackiness and is present in an amount sufficient to increase surface friction of the second major surface of the fibrous mat.