Reinforcement membrane and methods of manufacture and use

Abstract

A roadway reinforcement membrane has a composite reinforcement layer of reinforcement fibers in a matrix of polymeric material, wherein the reinforcement layer is an intermediate layer between a top veil and a bottom veil, and wherein the bottom veil can be applied with a coating for adherence to a roadway course; and wherein the top veil can be applied with a coating for adherence to road surfacing material.

1 . A reinforcement membrane, comprising: 
 a composite reinforcement layer containing reinforcement fibers in a matrix of polymeric material;    a bottom veil secured on a bottom of the composite reinforcement layer, wherein the bottom veil comprises a material to which an adherent asphalt-based cementitious material is applied; and    a top veil of fibers secured on a top of the composite reinforcement layer, wherein the top veil comprises a material to receive an adherent asphalt-based cementitious material.    
   
   
       2 . The reinforcement membrane according to  claim 1 , wherein the bottom veil and the top veil are bonded to the reinforcement layer.  
   
   
       3 . The reinforcement membrane according to  claim 1 , further comprising: 
 a bottom layer of an adherent asphalt-based cementitious material at least partially imbedding the veil and adhering to the reinforcement layer.    
   
   
       4 . The reinforcement membrane according to  claim 1 , further comprising: 
 a bottom layer of an adherent asphalt-based cementitious material at least partially imbedding the bottom veil and adhering to the reinforcement layer; and    a peel-off release film covering the bottom layer.    
   
   
       5 . The reinforcement membrane according to  claim 1 , further comprising: 
 a bottom layer of an adherent asphalt-based cementitious material at least partially imbedding the bottom veil and adhering to the reinforcement layer;    an adhesive covering the bottom layer; and    a peel-off release film covering the adhesive.    
   
   
       6 . A method of making a reinforcement membrane comprising: 
 securing top and bottom veils onto respective surfaces of a reinforcement layer comprising reinforcement fibers and a polymeric material; and    consolidating the reinforcement layer by melting the polymeric material while under pressure and re-solidifying same.    
   
   
       7 . The method of  claim 6 , further comprising: at least partially covering the bottom layer of adherent asphalt-based cementitious material with a peel-off release film.  
   
   
       8 . The method of  claim 6 , further comprising: 
 at least partially covering the bottom layer of adherent asphalt-based cementitious material with an adhesive backing; and    at least partially covering the adhesive backing with a peel-off release film.    
   
   
       9 . The method of  claim 6 , further comprising: 
 at least partially embedding the top veil in a top layer of an adherent asphalt-based cementitious material adapted for adherence to asphalt-based road surfacing materials.    
   
   
       10 . The method of  claim 6 , further comprising: 
 applying a first layer of an adherent asphalt-based cementitious material onto a lower course of a roadway;    applying the reinforcing membrane to the first layer of adherent asphalt-based cementitious material, wherein the reinforcing membrane comprises, a top veil of fibers and a bottom veil of fibers respectively covering and secured onto a reinforcement layer comprising reinforcement fibers joined to a polymeric material;    at least partially embedding at least the bottom veil in the first layer of adherent asphalt-based cementitious material;    applying a second layer of an adherent asphalt-based cementitious material onto the reinforcing membrane;    at least partially embedding at least the top veil in the second layer of adherent asphalt-based cementitious material;    applying a hot asphalt-based road surfacing material to the second layer of adherent asphalt-based cementitious material; and    consolidating the hot asphalt-based road surfacing material and the second layer of adherent asphalt-based cementitious material to form a unified structure at least between the top veil and the consolidated reinforcement layer.    
   
   
       11 . A roadway reinforcement membrane, comprising: 
 a pair of veils, each of said veils containing first fibers having a first melting point; and    a composite reinforcement layer core disposed between said pair of veils, said composite reinforcement layer core containing reinforcement fibers at least partially embedded in a thermoplastic matrix, said thermoplastic matrix having a second melting point lower than said first melting point; and at least a first surface of each of said pair of veils is bonded to said composite reinforcement layer core by a portion of said thermoplastic matrix.    
   
   
       12 . The roadway reinforcement membrane of  claim 11 , wherein at least a second surface of at least one of said pair of veils is permeated with an adherent asphalt based cementitious material.  
   
   
       13 . The roadway reinforcement membrane of  claim 11 , wherein the adherent asphalt based cementitious material is covered by a peel-off release film.  
   
   
       14 . The roadway reinforcement membrane of  claim 11 , wherein said composite reinforcement layer core comprises consolidated reinforcement fibers and thermoplastic fibers.  
   
   
       15 . A reinforment membrane product comprising: 
 a reinforcement layer comprising consolidated commingled fibers; and    a pair of veil layers, between which the reinforcement layer is laminated, the veil layers comprising a material to which a coating can be applied for improving a bond between the veil layers and an asphalt cement.    
   
   
       16 . The product of  claim 15 , wherein the reinforcement layer is a sheet, mat or open grid.  
   
   
       17 . The product of  claim 15 , wherein the reinforcement layer is an open grid, and the veil layers have perforations aligned with openings in the grid.  
   
   
       18 . The product of  claim 15 , wherein the consolidated commingled fibers are formed from reinforcement and one of the group consisting of polypropylene and polyester fibers.  
   
   
       19 . The product of  claim 15 , wherein the veil layer comprises one of the group consisting of polyester, polypropylene and cotton.  
   
   
       20 . A product comprising: 
 a reinforcement layer comprising consolidated commingled fibers; and    a pair of veil layers, between which the reinforcement layer is laminated, the veil layers comprising a material to which a coating material can be applied for improving a bond between the veil layers and an asphalt cementitious material.