Non-Uniform Coated Membrane for Architectural Wraps
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Solution Overview
Problem
Existing self-adhesive, vapor permeable air and moisture barrier membranes require uniform coatings, which may not be suitable for all applications, and existing methods for applying non-uniform coatings are limited in flexibility and effectiveness.
Innovation Solution
A self-adhesive, vapor permeable air and moisture barrier membrane with a substrate coated in a first pattern that is continuous in the longitudinal direction and discontinuous in the cross direction, and a second pattern that is continuous in the longitudinal direction and discontinuous in the cross direction, forming coating-free zones completely surrounded by both coatings, allowing for varied adhesive materials and patterns such as sinusoidal or straight patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform coating is applied to the substrate, then the coating coverage is complete and consistent, but the adaptability to different surface conditions and applications is reduced
Solution Approach 1:
The patent applies different coating patterns (first pattern and second pattern) to different regions of the substrate, creating local variations in coating properties. This allows the membrane to adapt to different surface conditions in different areas while maintaining controlled manufacturing through defined pattern geometries.
2Adaptability or versatility
If a non-uniform coating pattern is applied, then the adaptability to different applications is improved, but the manufacturing complexity increases
Solution Approach 1:
The coating is divided into multiple discrete patterns (first pattern and second pattern) that can be independently controlled and applied. This segmentation allows for flexible application to different surfaces while maintaining manageable manufacturing complexity through modular pattern design.
Solution Approach 2:
The membrane combines multiple coating patterns with different properties on a single substrate, creating a composite structure that provides both adhesion and vapor permeability in different regions, enhancing overall application flexibility.
3Reliability
If adhesive coating is applied continuously, then the adhesion strength is maximized, but the vapor permeability is reduced
Solution Approach 1:
The adhesive coating is applied in specific localized patterns rather than continuously, creating regions of high adhesion (where patterns contact) and regions of vapor permeability (coating-free zones). This resolves the contradiction by providing both strong adhesion where needed and vapor transmission where required.
Solution Approach 2:
Coating-free zones are intentionally created by removing adhesive material from specific areas, extracting the harmful effect of continuous coating (reduced vapor permeability) while retaining the beneficial effect in patterned regions (adhesion strength).
Data Source
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AI summary
An apparatus and process for applying a coating material onto a substrate as a non-uniform layer of coating material, the method including providing a distribution manifold having a cavity and a plurality of dispensing outlets in fluid communication with the cavity, creating relative motion between a substrate and the dispensing outlets in a first direction, and dispensing coating material from the dispensing outlets while simultaneously translating the plurality of dispensing outlets in a second direction non-parallel to the first direction. Using the process, coated articles having a useful non-uniform coating or coatings can be prepared, in particular self-adhesive vapor permeable air and moisture barrier membranes for use as architectural structure wraps.