Dual-Compound Fleece Membrane to Prevent Delamination
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Solution Overview
Problem
Existing fleece back construction membranes with multiple substrates are difficult to manufacture, expensive, and prone to delamination at the adhesive interface, leading to material failure during service life.
Innovation Solution
A single fleece substrate is used with a dual compound saturation process, where a first compound penetrates halfway through the substrate, followed by partial removal and application of a second compound, and a side lap compound is applied along one edge, preventing delamination by ensuring the unsaturated portion remains intact during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple substrates and membranes are used in fleece back construction membranes, then adhesive bonding strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple substrates and membranes into a single fleece substrate structure. The single substrate is saturated with adhesive compounds during manufacturing to achieve bonding strength without requiring multiple separate layers, thereby reducing manufacturing complexity while maintaining adhesive performance
Solution Approach 2:
The patent uses a single fleece substrate that is saturated with adhesive compounds (such as asphalt or bitumen) to create a composite structure. This composite approach provides the bonding strength of multiple materials while simplifying the overall construction to a single substrate type, reducing manufacturing steps and costs
2Strength
If multiple substrates and membranes are used in fleece back construction membranes, then adhesive bonding strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functional layers into a single fleece substrate that is saturated with adhesive during manufacturing. This eliminates the need to purchase and install multiple separate substrates and membranes, reducing material costs and simplifying the manufacturing process while maintaining bonding strength
Solution Approach 2:
The single fleece substrate is pre-saturated with adhesive compounds during manufacturing, making the adhesive application self-contained within the product itself. This eliminates the need for separate adhesive application steps and reduces overall manufacturing costs while ensuring adequate bonding strength
3Strength
If adhesive is applied to fleece substrate interface, then bonding is achieved, but delamination occurs during service life
Solution Approach 1:
The adhesive compounds are applied and saturated into the fleece substrate during the manufacturing process before the product is installed. This preliminary saturation ensures that the adhesive is already distributed throughout the substrate structure, creating strong bonds that resist delamination during service life without requiring additional field application
Solution Approach 2:
The fleece substrate's porous structure allows adhesive compounds to penetrate and saturate the fibers during manufacturing. This saturation creates strong mechanical interlocking and chemical bonding within the substrate matrix, preventing delamination at the adhesive interface during service life while maintaining flexibility and adhesion
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 solution prevents delamination of the fleece substrate during and after installation, offering a cost-effective and durable construction material with improved adhesive properties for overlapping membranes.
Implementation Method 1
a first compound is applied to a bottom side of the single fleece substrate that penetrates the single fleece substrate about halfway
Implementation Method 2
The adhered fleece material can delaminate at the adhesive interface between the fleece and membrane causing material failure during their service life
Data Source
AI summary
A construction material with an exposed fleece surface including (i) a planar fleece substrate having first and second opposed planar surfaces, (ii) said planar fleece type substrate is partially saturated on the first planar surface with a first compound that penetrates the fleece type substrate about half way, (iii) said first compound is then partially removed leaving a thin layer of first compound about half way between the first and second opposed planar surfaces of the fleece substrate, (iv) a second compound is applied on the first planar surface forming a fleece membrane with an exposed surface that is partially saturated with two distinct compounds, (v) and said second compound or a different third compound is applied along one edge of the exposed second planar fleece surface of the fleece substrate forming a side lap along the length of the fleece membrane.