Roofing Membrane Resin Composition for Flexibility and Tear Strength
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Solution Overview
Problem
Roofing membranes, such as those made from thermoplastic polyolefins, lack flexibility to cover various roof topologies while increasing flexibility reduces mechanical strength, compromising durability and protection.
Innovation Solution
A roofing membrane composed of a blend of non-moisture curable and moisture curable resins, where the non-moisture curable resin is cured and the moisture curable resin, which includes silicon, is uncured and cures upon exposure to moisture, providing flexibility and meeting ASTM D6878 tear strength requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the roofing membrane is made from traditional thermoplastic polyolefins (TPO), then it provides mechanical strength and rigidity, but it lacks flexibility to cover various roof topologies
Solution Approach 1:
The patent applies composite materials by combining two distinct resin systems (non-moisture curable resin and moisture curable resin) into a single roofing membrane formulation. This composite approach allows the membrane to exhibit both flexibility from the moisture curable resin component and mechanical strength from the non-moisture curable resin component, resolving the contradiction between flexibility and strength.
Solution Approach 2:
The patent utilizes parameter changes through the moisture curable resin that transitions from an uncured flexible state during installation to a cured strong state after exposure to moisture. This temporal parameter change allows the membrane to be flexible when needed for installation and strong when needed for structural integrity, effectively resolving the flexibility-strength contradiction.
2Adaptability or versatility
If the flexibility of the roofing membrane is increased to cover various roof topologies, then adaptability improves, but mechanical strength is reduced, compromising durability
Solution Approach 1:
The patent applies preliminary action by pre-formulating the membrane with both resin systems in a way that the non-moisture curable resin provides immediate structural support and durability, while the moisture curable resin provides initial flexibility for installation. The sequential curing process ensures durability is maintained throughout the membrane's service life.
Solution Approach 2:
The composite material system resolves the flexibility-durability contradiction by integrating two resin systems with complementary properties: the non-moisture curable resin ensures long-term durability and structural integrity, while the moisture curable resin provides the necessary flexibility for installation and adapts to various roof topologies.
3Ease of operation
If a moisture curable resin is used to provide flexibility, then the membrane remains uncured and flexible during installation, but it requires moisture exposure to achieve full strength
Solution Approach 1:
The patent applies preliminary action by incorporating the non-moisture curable resin that is already cured and provides immediate structural support during installation, while the moisture curable resin remains uncured to provide flexibility. This preliminary structural support eliminates the weakness period that would otherwise exist during the curing process.
Solution Approach 2:
The non-moisture curable resin acts as an intermediary that provides immediate structural support and durability during installation, while the moisture curable resin provides flexibility. The two resin systems work together, with the non-moisture curable resin compensating for the uncured state of the moisture curable resin during the installation phase.
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 roofing membrane achieves enhanced flexibility and durability, with a tear strength of 55 lbf to 140 lbf when exposed to moisture, outperforming traditional TPO membranes in terms of flexibility and mechanical strength.
Implementation Method 1
the second resin is moisture curable. In some embodiments, the second resin is uncured. In some embodiments, the roofing membrane, when exposed to moisture, exhibits a tear strength that meets ASTM D6878
Data Source
AI summary
A roofing membrane includes a plurality of resins present in an amount of 30 wt. % to 100 wt. % based on a total weight of the roofing membrane. The plurality of resins include a first resin and a second resin. The first resin includes a resin present in an amount of 20 wt. % to 80 wt. % based on a total weight of the plurality of resins in the roofing membrane; that is not moisture curable; and that is cured. The second resin includes a resin present in an amount of 20 wt. % to 80 wt. % based on the total weight of the plurality of resins in the roofing membrane; that is moisture curable; that is uncured; and includes silicon. The roofing membrane is flexible. The roofing membrane, when exposed to moisture, exhibits a tear strength that meets ASTM D6878.