Filled Sealing Membrane Composition for Early Concrete Adhesion
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Solution Overview
Problem
Existing waterproofing membranes exhibit poor early adhesion strength to fresh concrete, leading to potential detachment when formwork is removed within 24 hours, and often require additional layers or materials that increase production costs.
Innovation Solution
A sealing device with a functional layer composed of a highly-filled thermoplastic polymer containing at least two different types of solid fillers, each with distinct particle sizes and properties, enhances early adhesion strength to concrete without significantly increasing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layer polymer-based barrier layer is used for waterproofing, then the structure is simple and production cost is low, but the adhesion strength to fresh concrete is poor
Solution Approach 1:
The patent applies composite materials by combining a polymer-based barrier layer with a contact layer made of highly-filled thermoplastic polymer composition containing mineral fillers and hydraulic binders. This composite structure improves adhesion strength to fresh concrete while maintaining reasonable structural complexity through integrated layer bonding.
Solution Approach 2:
The patent applies local quality by creating a specialized contact layer with specific local properties (high mineral filler content, hydraulic binder presence) that is tailored for adhesion to concrete, while the barrier layer maintains its waterproofing properties. Each layer has optimized local characteristics for its specific function.
2Strength
If a contact layer with non-woven fabric is added to improve bonding, then adhesion strength improves, but production cost increases and seam sealing capability deteriorates
Solution Approach 1:
The patent applies porous materials by using a highly-filled thermoplastic polymer composition with mineral fillers that creates a porous or rough surface structure on the contact layer. This structure enhances mechanical interlocking with fresh concrete, improving bonding strength without requiring additional non-woven fabric layers.
Solution Approach 2:
The contact layer is formulated as a composite material with thermoplastic polymer, mineral fillers, and hydraulic binders, replacing the need for separate non-woven fabric adhesive layers. This integrated composite approach reduces production costs while maintaining improved bonding performance.
3Strength
If a contact layer with non-woven fabric is used, then bonding to concrete is improved, but heat-welding of seams becomes difficult
Solution Approach 1:
The highly-filled thermoplastic polymer composition creates a porous surface structure that enhances bonding while remaining compatible with heat-welding processes. The porous structure provides mechanical interlocking without preventing thermal energy transfer needed for seam sealing.
Solution Approach 2:
The contact layer uses thermoplastic polymer composition that can undergo parameter changes (melting and solidification) during heat-welding. The material's thermal properties are optimized to allow seam sealing while maintaining bonding strength to concrete.
4Strength
If adhesive layers are added to secure contact layer, then bonding strength improves, but production cost increases
Solution Approach 1:
The contact layer is designed to be self-adhesive to fresh concrete through its composition of hydraulic binders and mineral fillers that chemically and mechanically bond with concrete. This self-service capability eliminates the need for separate adhesive layers, reducing production costs while maintaining bonding strength.
Solution Approach 2:
The contact layer is formulated as a composite material with inherent bonding properties through hydraulic binders and mineral fillers, replacing the need for separate adhesive layers. This integrated composite approach reduces the number of components and production costs.
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 sealing device achieves high early adhesion strength, allowing formwork removal after 24 hours without detachment, while maintaining cost-effectiveness compared to existing technologies.
Implementation Method 1
the functional layer (2) comprises: a) 20-75 wt.-%, preferably 25-70 wt.-%, of at least one thermoplastic polymer P1 and b) 25-80 wt.-%, preferably 30-75 wt.-%, of a solid filler component F... the at least one first solid filler F1 comprises at least one hydraulic binder F12
Implementation Method 2
The waterproofing membrane can be produced by co-extruding melt-processed compositions of the barrier layer and the functional layer... membranes composed of TPOs are heat-weldable
Data Source
AI summary
A sealing device and a method for producing a sealing device and to use of a sealing device for waterproofing of a substrate, the sealing device including a functional layer having a first major surface and a second major surface and a barrier layer directly or indirectly connected to the second major surface of the functional layer, wherein the functional layer includes at least one first solid filler having a median particle size d50 in the range of 0.5-100 μm and at least one second solid filler different from the at least one first solid filler.