Cross-Laminated Waterproof Membrane for Seamless Curved Surfaces
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Solution Overview
Problem
Existing waterproof materials for building structures, such as walls and floors, are not inherently flexible, prone to degradation, and require seams, which can lead to water and moisture incursion, especially in high-moisture environments like bathrooms and showers.
Innovation Solution
A waterproof membrane composed of polypropylene non-woven layers, a high-density polyethylene cross-laminated film, and a polyolefin tie layer, which is flexible and seam-free, allowing application in corners and curved areas without joints, and provides high strength and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid waterproof boards (e.g., cement board, KERDI-BOARD) are used, then waterproofing performance is improved, but flexibility and ease of application in corners and curved areas deteriorates
Solution Approach 1:
The patent employs a flexible membrane composed of multiple layers including non-woven fabric layers and a cross-laminated film layer. This flexible film structure can conform to corners, curved areas, and complex surfaces while maintaining waterproofing performance, eliminating the need for rigid boards that cannot adapt to such geometries.
Solution Approach 2:
The waterproof membrane is constructed as a composite material system with multiple layers: non-woven fabric layers for flexibility and adhesion, a cross-laminated film layer for waterproofing strength, and tie layers for bonding. This composite structure integrates the advantages of different materials to achieve both flexibility and reliable waterproofing.
2Area of stationary object
If seams and joints are used in waterproof substrates, then coverage of large surfaces is achieved, but water incursion risk and degradation potential increase
Solution Approach 1:
The flexible membrane can be applied in large continuous sheets without seams or joints, maintaining continuous waterproof protection across the entire surface. This eliminates the discontinuities created by seams and joints in traditional board systems, preventing water incursion at joint locations.
Solution Approach 2:
The patent transitions from dimensional board systems that require seams to a continuous film system that can cover large areas without interruptions. The membrane's flexibility allows it to be applied as large continuous sheets, eliminating the need for dimensional segmentation that creates vulnerable joint areas.
3Adaptability or versatility
If thin flexible membranes are used, then flexibility and ease of application are improved, but strength and resistance to tears and punctures deteriorates
Solution Approach 1:
The membrane combines multiple materials in a layered composite structure: non-woven fabric layers provide flexibility and tear resistance, while the cross-laminated film layer provides puncture resistance and waterproofing strength. The tie layers bond these components together, creating a unified structure where each layer contributes its specific strengths.
Solution Approach 2:
Each layer in the composite membrane serves multiple functions: the non-woven fabric layers provide both flexibility for application and tensile strength, while the cross-laminated film provides both waterproofing and puncture resistance. This multi-functional design allows the thin membrane to achieve both flexibility and strength simultaneously.
Data Source
AI summary
A waterproof extrusion laminated flexible membrane that may be seamlessly applied to an irregularity on a substrate supporting a finished surface for waterproofing that includes first and second polypropylene non-woven layers each having first and second surfaces, a water impermeable HDPE oriented cross laminated film layer, a first tie layer between the first non-woven first surface and the cross laminated film layer, and a second tie layer between the second non-woven first surface and the cross laminated film layer. Other membranes and methods are also disclosed.