Waterproofing Membrane Without Release Liner
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Solution Overview
Problem
Conventional waterproofing membranes for concrete applications require a removable release sheet, leading to environmental waste, labor inefficiencies, and potential delamination under extreme water immersion conditions, while also facing challenges with UV exposure and foot traffic resistance.
Innovation Solution
A waterproofing membrane with four laminated layers: a carrier sheet, a waterproofing adhesive, a protective coating free of surfactants, and a releasable material comprising amorphous nanoscale silica and a polymeric binder, arranged in the order A-B-C-D, which allows for easy unrolling without a release liner and maintains bond strength under water immersion and UV exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a removable release sheet is used to prevent adhesive adhesion to the carrier sheet, then the membrane can be rolled up without adhesion issues, but environmental waste increases and labor inefficiencies occur due to removal and disposal
Solution Approach 1:
The patent extracts the release function from a separate removable sheet and integrates it directly into the carrier sheet through a release coating. This eliminates the need for a separate release sheet component, allowing the membrane to be rolled up without adhesion issues while generating no waste material for removal and disposal.
Solution Approach 2:
The release function is merged with the carrier sheet by applying a release coating directly to it. This combines the structural support function of the carrier sheet with the adhesion prevention function of the release sheet, creating a single integrated component that eliminates waste and reduces labor.
2Reliability
If a removable release sheet is used to protect the adhesive portion, then adhesion protection is achieved, but labor costs increase due to removal and disposal requirements
Solution Approach 1:
The release function is extracted from a separate removable component and integrated into the carrier sheet itself. This eliminates the labor-intensive removal and disposal steps while maintaining adhesive protection during storage and transport.
Solution Approach 2:
The carrier sheet with integrated release coating serves its own release function without requiring external intervention for removal. The release coating automatically prevents adhesion during rolling and storage, and can be easily removed during installation without specialized labor or tools.
3Reliability
If conventional membranes with release sheets are used, then adhesion prevention is achieved, but potential delamination occurs under extreme water immersion conditions
Solution Approach 1:
The release function is extracted from a separate removable sheet and integrated as a thin coating layer on the carrier sheet. This eliminates the interface between separate layers that could delaminate under water immersion, while maintaining adhesion prevention functionality.
Solution Approach 2:
The patent creates a composite structure where the carrier sheet and release coating form an integrated system with improved interfacial bonding. The release coating is chemically or physically bonded to the carrier sheet, creating a stable composite that resists delamination under extreme conditions while providing release functionality.
4Reliability
If the protective coating is made slippery to protect the adhesive, then adhesive protection is improved, but foot traffic resistance deteriorates
Solution Approach 1:
The patent applies different functional properties to different locations or layers: the release coating provides a slippery, low-friction surface for adhesion protection, while the top protective coating provides high friction for foot traffic resistance. Each layer is optimized for its specific function without compromising the other.
Solution Approach 2:
The protective functions are segmented into separate layers: the release coating handles adhesive protection with its slippery properties, while a separate top protective coating handles foot traffic resistance with its high-friction surface. This segmentation allows each layer to be optimized independently for its specific function.
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 membrane achieves strong adhesion to concrete, withstands water immersion, and tolerates foot traffic without the need for a release sheet, reducing environmental impact and labor costs while maintaining performance over time.
Implementation Method 1
a releasable material, wherein the releasable material comprises amorphous nanoscale silica, wherein the nanoscale silica has a particle size of 0.1 nm to 150 nm, and a polymeric binder
Implementation Method 2
a pressure sensitive adhesive layer
Implementation Method 3
a protective coating, wherein the protective coating is substantially free of surfactant such that the amount of surfactant is, by weight of polymer in layer C, from 0 to 1.0%
Data Source
Figure 1
AI summary
Disclosed is a waterproofing membrane that comprises a carrier sheet (layer A); a waterproofing adhesive (layer B); a protective coating (layer C), wherein the protective coating is substantially free of surfactant and comprises an acrylic or methacrylic polymer or copolymer, an inorganic filler and a white pigment; and a releasable material (layer D), wherein the releasable material comprises amorphous nanoscale silica and a polymeric binder. The waterproofing membrane does not require a release liner, binds strongly to concrete cast against it (even after UV exposure), tolerates foot traffic, and withstands immersion in water over an extended period.