Embossed Single Ply Roofing Membrane Anti-Roll Blocking
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Solution Overview
Problem
Single ply roofing membranes tend to experience roll blocking issues due to smooth surfaces causing portions to stick and adhere during unwinding and storage, which hinders the unwinding process and installation.
Innovation Solution
A single ply roofing membrane with a bottom layer embossed with various patterns to increase the surface area, combined with a polyolefin top and bottom layer and a fibrous reinforcing scrim, where a small amount of highly-flowable, functional polyolefin is incorporated to enhance adhesion, and the bottom layer is embossed with patterns such as pyramidal, cone, or random configurations to reduce roll blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the membrane surface is made smooth, then the manufacturing process is simple, but roll blocking occurs causing portions to stick and adhere during storage and unwinding
Solution Approach 1:
The patent applies embossment only to specific localized areas of the membrane surface rather than the entire surface. This creates anti-roll blocking ridges at critical locations where blocking occurs during storage and unwinding, while leaving other areas smooth to maintain manufacturing simplicity and heat seaming performance.
Solution Approach 2:
The membrane surface is segmented into embossed regions and non-embossed regions. The embossed portions create physical separation between membrane layers at critical points, preventing adhesion and roll blocking, while maintaining overall manufacturing efficiency.
2Reliability
If embossment is applied to selvage edges only, then heat seaming performance is maintained, but roll blocking problem persists in the majority of surface area
Solution Approach 1:
The patent strategically locates embossment in specific zones that balance heat seaming requirements with anti-roll blocking needs. By positioning embossed ridges at appropriate distances from selvage edges and creating patterns that prevent blocking while preserving seam integrity, both requirements are satisfied simultaneously.
3Ease of operation
If complete embossment of the bottom layer is applied, then roll blocking is greatly reduced, but surface area and manufacturing complexity increase
Solution Approach 1:
Rather than embossing the entire bottom layer surface, the patent applies embossment only to specific strategic locations and patterns. This reduces roll blocking effectively while minimizing the increase in surface area and manufacturing complexity compared to complete embossment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The embossed bottom layer significantly reduces roll blocking, allowing for easier unwinding and installation by increasing the surface area and improving adhesion between layers, with blocking tests showing a reduction from 100% to approximately 25%.
Implementation Method 1
the bottom layer is embossed with various patterns to increase the surface area of the membrane
Implementation Method 2
To promote adhesion between the scrim and the polyolefin sheets, a highly flowable, functional-polyolefin is incorporated into one or both sheets
Data Source
AI summary
A single ply mechanically embossed roofing membrane in a roll form for use in commercial applications on flat and low pitched roofs. The roofing membrane preferably includes a scrim or reinforcement sheet sandwiched between a top layer and a bottom layer, wherein the bottom layer is completely embossed with various configurations forming alternating ridges and valleys. The embossed roofing membrane improves roll blocking upon installation. The embossed roofing membrane can be installed by fully adhering or mechanically attaching to the roof deck.