CN111527166A - 具有颗粒状聚合物外保护层的预铺膜 - Google Patents
具有颗粒状聚合物外保护层的预铺膜 Download PDFInfo
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- CN111527166A CN111527166A CN201780098117.XA CN201780098117A CN111527166A CN 111527166 A CN111527166 A CN 111527166A CN 201780098117 A CN201780098117 A CN 201780098117A CN 111527166 A CN111527166 A CN 111527166A
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Abstract
本发明提供一种预铺防水膜,其具有防水胶粘层和包含合成聚合物颗粒的外粒子层以保护胶粘层和促进膜‑膜搭接处的细部处理。在优选实施方案中,合成聚合物颗粒由选自聚乙酸乙烯酯、丙烯酸系和苯乙烯丁二烯共聚物或聚合物的聚合物制成。最优选地,合成聚合物颗粒具有圆形或球形形状,这有助于促进在建筑或铺设现场的细部处理,如膜搭接处的密封,和在管道或其它细部周围的密封。或者,该膜可被制成具有不含合成聚合物颗粒的侧边,由此可使用可除去的离型衬条防止在将膜自行卷绕以供运输时胶粘剂粘到膜的背面。
Description
发明领域
本发明涉及自粘防水膜,更特别涉及具有防水胶粘层和用于保护胶粘层并促进膜-膜搭接处的细部处理(detailing)的包含合成聚合物颗粒的外粒子层的预铺防水膜。
发明背景
在美国专利5,496,615(属于本文的共同受让人)中,Bartlett等人最先教导了使用“预铺”防水膜,其包括载体层、胶粘层和保护涂层。该膜以载体层侧紧贴模具或模板工程铺设,胶粘层和保护涂层朝外以可将混凝土浇注于其上并在固化和硬化时粘结到其上。
‘615专利描述了细碎粒子材料层的使用,其布置在保护涂层上以降低胶粘层和保护涂层的粘性,以使膜可耐受踩踏而不减损胶粘层和保护涂层与后浇混凝土的粘结能力(见第2栏,第52-57行)。Bartlett等人教导了这样的粒子材料可包含碳酸钙、砂、硅酸盐砂、水泥或滑石,优选粒度为大约0.1 – 1000微米(见第7栏,第50-61行)。在这些无机粒子中优选的是碳酸钙和砂,因为这些明显提供与随后浇注在粒子上(“后浇”)的混凝土的良好粘结能力。
在美国专利6,500,520(属于本文的共同受让人)中,Wiercinski等人教导了预铺防水膜,其中无机粒子与由水化混凝土生成的氢氧化物反应以形成水化产物。这些反应性无机粒子包括三水合氧化铝、二氧化硅(silica dioxide)、飞灰、高炉矿渣、硅粉和碱金属或碱土金属盐。Wiercinski等人教导了该粒子除飞灰和高炉矿渣外还可包括使用火山灰或火山灰材料,包括硅藻土、石灰石、粘土(例如偏高岭土)和页岩。火山灰,如硅质或铝硅质材料自身具有极小或不具有粘接价值(即作为粘合剂材料)。但是,在细碎形式下,这样的材料可与由水化水泥释放的氢氧化钙化学反应以形成具有粘接性质的材料,因此在将湿混凝土后浇在预铺膜上时有助于粘结强度(第3栏,第57-67行)。
在美国专利8,453,405和8,713,879(属于本文的共同受让人)中,Wiercinski等人教导了预铺防水膜,其中无机粒子基本为反射性质。该粒子优选由磨碎白水泥、磨碎水化白水泥、磨碎部分水化水泥或其混合物组成。这样的反射性无机粒子的使用看起来改进膜与后浇混凝土之间的粘结(参见例如第8栏第26行等)。此外,该膜不需要具有原本为防止在卷绕该膜时胶粘剂粘到载体片上而需要的可除去的离型纸。
预铺防水膜设计近年来和在其大部分历史中的发展集中于外层中的无机粒子材料。如上文概述,这包括矿物、水泥、水泥质材料(cementitious)、一种或多种火山灰和火山灰材料,这些都已赋予防水膜有用的功能。与保护涂层组合,这些功能包括保护防水胶粘层免受降解、踩踏和机械影响,以及促进与后浇混凝土的粘结和膜的卷绕/展开而不使用可除去的离型衬纸。
但是,对本发明人而言,无机粒子的使用提高在施工现场细部处理的难度。如此使用无机粒子提高将相邻膜连接(或搭接)在一起的难度和加重其所需的劳动力和时间。胶带与无机材料之间的不相容性(这导致粘连(blockage))属于本发明人通过本发明试图解决的问题。
发明概述
为了克服现有技术的缺点,本发明提供一种新颖性和创造性的预铺防水膜,其具有有两个主面的载体片层;紧贴载体片层的主面附着的防水胶粘层;和包含合成(有机)聚合物颗粒的粒子层。
本发明人相信,合成(有机)聚合物颗粒在外保护粒子层中的使用促进在施工现场的细部处理操作,特别是相邻膜的边缘搭接的连接或接合(seaming)在一起,以及促进在管道和在模板工程、混凝土地基和施工现场的其它细部中的其它突出物或凹槽周围形成屏障保护。
在优选实施方案中,防水膜的防水胶粘层的总面积的25%-100%被有机聚合物颗粒覆盖;更优选地,防水胶粘层的总面积的45%-100%被合成(有机)聚合物颗粒覆盖;最优选地,防水胶粘层的总面积的65%-100%被合成(有机)聚合物颗粒覆盖。
在替代性实施方案中,预铺膜具有侧边,沿着侧边,一部分防水胶粘层不含合成(有机)聚合物颗粒以允许防水胶粘层直接搭接到相邻膜的载体片的背面(并可沿着膜边缘在压敏胶粘剂上施加离型衬条以允许该膜的卷绕,并由此在铺设时除去离型衬条以使暴露的胶粘剂可粘到载体层的背面,由此可将相邻膜接合在一起)。
考虑用于本发明的示例性颗粒包含选自聚乙酸乙烯酯、丙烯酸系(例如PMMA)和聚苯乙烯和苯乙烯共聚物的合成(有机)聚合物。在优选实施方案中,该合成聚合物颗粒通过悬浮聚合制成。
在进一步的示例性实施方案中,可通过用聚合物涂布无机粒子,如碳酸钙、砂或其它无机材料形成合成聚合物颗粒。
本发明还涉及使用在外粒子层中具有有机聚合物颗粒的上述膜将基底和表面防水的方法。本发明的膜可施加到各种基底,包括模具和衬板(lagging)(例如混凝土模板工程)上,以及施加到砾石、混凝土、土壤保持系统、隧道壁和其它基底或表面上。
尽管可任选在向外的合成聚合物颗粒上使用保护涂层以进一步保护防水压敏胶粘剂(PSA)层,但本发明人相信,合成(有机)聚合物颗粒的使用可为防水PSA层提供足够的保护而不用任选的保护涂层。
在进一步的示例性实施方案中,可在合成聚合物颗粒上、之间、或在合成聚合物颗粒上和之间施加涂层以为该膜提供防滑性。
下面详细描述进一步的优点和特征。
附图简述
当结合附图考虑优选实施方案的下列详述时,更容易认识到本发明的进一步优点和特征,其中:
图1是包括载体片层、防水胶粘层、紧贴防水压敏胶粘层布置、附着于防水压敏胶粘层或部分嵌入防水压敏胶粘层中的粒子层的本发明的示例性预铺防水膜的横截面的图示说明(并非按比例绘制);且
图2是具有部分嵌入防水压敏胶粘层中的合成聚合物粒子的本发明的另一示例性防水膜的通过光学显微镜(在50X放大率下)拍摄的显微照片。
示例性实施方案的详述
图1图示说明本发明的示例性预铺防水膜10,其包括具有两个主面的柔性载体片层12;具有两个主面的防水压敏胶粘层14,其一个主面附着于所述载体片层12的一个主面;和在防水胶粘层14外侧的包含合成聚合物颗粒的粒子层16。
在进一步的示例性实施方案中,可以使用任选保护涂层(未图示说明),其在粒子层16上、或在防水胶粘层14和粒子层16之间、或在粒子层16内的粒子之间或其组合,以为防水胶粘层14提供进一步的保护。尽管本发明人相信,粒子层16可足以保护防水胶粘层14免受踩踏和磨损,但在粒子的向外面上和/或在粒子(16)之间的任选保护涂层可提供其它有帮助的性质,如改进的防滑性、UV防护或其它有益的性质。
图2是描绘本发明的示例性防水膜的示例性合成聚合物粒子(在图1中标作16)的光学显微镜照片,其中聚合物粒子部分嵌入胶粘层中。在50X放大率下拍摄图2的显微镜照片。显而易见,聚合物粒子提供粗糙表面积以在铺设该膜时耐受踩踏以及提供某些防粘连益处。尽管图2中所示的粒子的圆形或球形对实现这些特征是优选的,但本发明不限于这样的圆形或球形,因为粒子层中的合成聚合物颗粒可呈现任何种类的形状,如不规则形状,或具有由聚合物材料机械研磨到较小粒度产生的研磨或破裂表面的粒子。
考虑用于本发明的示例性载体片层12可由热塑性塑料、橡胶或连续膜形式的金属、织造材料、玻璃或无纺材料制成。特别适用于本发明的热塑性塑料包括聚丙烯、聚乙烯、乙烯-丙烯共聚物、聚苯乙烯(PS)、乙烯-烯烃共聚物、乙烯-乙酸乙烯酯共聚物、聚乙酸乙烯酯、聚丙烯酸乙酯、聚四氟乙烯(PTFE)、聚偏二氟乙烯(PVDF)、聚对苯二甲酸乙二醇酯(PET)、聚氯乙烯(PVC)、聚酰胺及其组合。
优选的载体片层12包括高密度聚乙烯(HDPE)的热塑性膜。织物可以是织造织物或无纺织物并可包含聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯和聚酰胺。织造聚丙烯织物也特别合适。柔性载体层12可包括含有热塑性塑料、橡胶或连续膜形式的金属、织造材料、玻璃或无纺材料的两个或更多个片材的层压材料。柔性载体层12也可以是共挤出多层膜或片材,或是连续膜、织造材料或无纺材料。
适用于本发明的示例性的柔性载体片层12材料应该为预铺防水膜10的结构提供机械强度和防水完整性。载体层12应该优选具有大约0.05至2.0 mm,更优选大约0.3至1.0mm的厚度。载体层12应该进一步具有大致光滑表面,如由膜、片材、织物和挤出涂布的织造织物或无纺织物提供。
通常,载体层或片12未经表面处理以提高表面张力。但是,在一些情况下,可能希望处理要在其上施加胶粘剂14的载体片12的表面以增强胶粘层14对载体片12的附着力。表面处理的一个实例是电晕处理。
可将添加剂并入载体层12材料中。载体层12可含有一种或多种添加剂,如抗氧化剂、热稳定剂、光稳定剂、阻燃剂、填料、增塑剂、抗静电剂、颜料、加工助剂、anti-roots、抗微生物剂等。这些可在单独配混步骤中并入材料本体中。添加剂也可在熔体挤出法以制造片材、膜或挤出涂布织物的过程中并入材料本体中。
最适用于本发明的示例性防水胶粘层14应该为膜10提供防水完整性。防水胶粘层14部分或完全用于将粒子层16粘结到载体片12上。在本发明中可以使用沥青质或橡胶改性的沥青质胶粘剂。为了改进在施工现场UV暴露后对后浇混凝土的附着力,更优选基于合成聚合物的防水胶粘剂14。胶粘层14优选具有如根据ASTM D 5-73测得的大于大约30丝米(dmm)(150 g,5 s,70℉)的针入度(penetration)。
本文所用的术语“基于合成聚合物的防水胶粘剂”是指用于防水胶粘层(在图1中标作14)的非沥青质(non-bituminous)或不含沥青(non-asphaltic)的胶粘剂。本发明的示例性的非沥青质或合成胶粘层包含基于丁基橡胶的胶粘剂、基于聚异丁烯的胶粘剂、基于聚异丁基的胶粘剂、基于丙烯酸系的胶粘剂、基于苯乙烯-异戊二烯-苯乙烯(SIS)的胶粘剂、基于苯乙烯-乙烯-丙烯-苯乙烯(SEPS)的胶粘剂、基于苯乙烯-丁二烯-苯乙烯(SBS)的胶粘剂、基于苯乙烯-乙烯-丁烯-苯乙烯(SEBS)的胶粘剂、基于苯乙烯-丁二烯橡胶(SBR)的胶粘剂及其组合。压敏胶粘剂(PSA)是优选的。优选地,合成胶粘剂是SIS、SBS、SEBS或SEPS及其组合的压敏热熔胶粘剂嵌段共聚物。关于压敏胶粘剂的更详细描述,参见Satas,Handbook Of Pressure Sensitive Adhesive Technology, (Van Nostrand ReinholdCompany, Inc., 1982)。基于合成聚合物的胶粘层应该优选具有大约3至30密耳,更优选大约5至15密耳,最优选大约8至10密耳的厚度。
此外,适用于胶粘层14的橡胶或弹性体包括聚氨酯、聚异戊二烯、聚丁二烯、天然橡胶、氯丁橡胶、乙烯-丙烯橡胶、乙烯α烯烃、丁腈橡胶、丙烯酸系橡胶或其混合物。
另外的示例性胶粘层14包含一种或多种非晶聚烯烃。非晶聚烯烃(APO)被定义为具有如通过差示扫描量热法测得的小于30%的结晶度的聚烯烃。这些聚合物可以是丙烯的均聚物或丙烯与一种或多种α-烯烃共聚单体,例如乙烯、1-丁烯、1-己烯、1-辛烯和1-癸烯的共聚物。如同基于橡胶的胶粘剂,该聚合物也与增粘剂和增塑剂组合以产生PSA组合物,其可涂布到载体层12上。参见例如Eastman bulletin “Pressure-Sensitive AdhesivesBased on Amorphous Polyolefin From Eastman Chemical Company”。
尽管较不优选,但也可将沥青质PSA材料,包括用橡胶和/或其它添加剂改性的组合物热熔涂布到载体层或片上。沥青质或橡胶改性的沥青质胶粘层应该优选具有10至200密耳的厚度。
本发明中的防水胶粘层14可任选含有常用于防水膜的添加剂,包括但不限于光吸收剂(例如炭黑、苯并三唑类等)、光稳定剂(例如受阻胺、二苯甲酮)、抗氧化剂(例如受阻酚)、填料(例如碳酸钙、二氧化硅、二氧化钛等)、增塑剂、流变添加剂及其混合物。优选的组合是包含光吸收剂、光稳定剂、抗氧化剂或其混合物的合成PSA。在本发明的进一步的示例性实施方案中,这些任选添加剂之一也可包含在聚合物粒子层16中。
本发明中的胶粘层14可任选含有热塑性塑料、橡胶或连续膜形式的金属、织造材料、玻璃或无纺材料的增强层。
如上文提到,本发明的示例性防水膜可任选包括保护涂层(未显示在图1或2中),如紧贴外粒子层(16)施加以额外保护防水胶粘层,或用于其它用途(如提高摩擦以提供可通行性(trafficability)、防滑性等)。在背景部分中论述的许多现有技术参考文献中公开了保护涂层。但是,本发明人相信,合成(有机)聚合物颗粒在外粒子层(16)中的使用提供保护方面,其令人惊讶地在很大程度上消除过去对保护涂层的依赖,这是本发明的额外益处。
最后,如上文论述,在防水胶粘层14上形成包含合成聚合物颗粒的粒子层16(任选具有一种或多种如在背景部分的现有技术论述中提到的无机粒子)。含聚合物颗粒的粒子层16有效保护胶粘层16免受灰尘、污物和自然环境(elements)(特别是太阳光)的影响。优选地,粒子层16内的有机聚合物颗粒具有1 µm至1000 µm的平均直径;更优选大约100 µm至600 µm的平均直径。通过激光衍射技术测量平均粒径。作为体积等效球体直径测量粒度。合适的市售设备可获自Malvern并以商标名Mastersizer™ 2000和Mastersizer™ 3000出售。通过将合成聚合物颗粒,任选与无机粒子(例如白水泥、三水合铝等)一起,部分嵌入胶粘层14的第二主面(与附着于载体层12的主面相对)中,形成粒子层16,由此粒子体16的一部分相对于胶粘层14未淹没。
在进一步的示例性实施方案中,粒子层16的涂布重量优选为100至700克/平方米;更优选地,粒子层的涂布重量为200至400克/平方米。
粒子层16与后浇混凝土形成机械互锁以形成与所得结构的强粘结,改进膜10的防滑性和改进膜10在铺设过程中的可通行性(耐踩踏性)。
粒子的形状可以是规则或不规则的。球形粒子可被视为具有规则形状。这样的聚合物粒子可通过悬浮聚合制成。或者,该粒子可具有不规则形状。例如,可通过各种研磨法制造粒子,以产生不规则形状的粒子。
用于形成合成聚合物颗粒的合成聚合物材料可选自有机聚合物,包括但不限于聚烯烃(例如聚乙烯、聚丙烯或其混合物)、聚环氧乙烷、聚丙二醇、聚乙酸乙烯酯、乙烯-乙酸乙烯酯共聚物、丙烯酸均聚物或共聚物、丙烯酸酯均聚物或共聚物、丙烯酸/丙烯酸酯共聚物、烯烃/丙烯酸共聚物、烯烃/丙烯酸酯共聚物、马来酸酐/丙烯酸共聚物、苯乙烯共聚物如苯乙烯/丙烯酸系共聚物和苯乙烯/丙烯酸酯共聚物、马来酸酐共聚物如苯乙烯/马来酸酐共聚物、马来酸酐/烯烃共聚物、乙酸乙烯酯/马来酸酐共聚物;增粘树脂如松香树脂或改性松香树脂、萜烯树脂或改性萜烯树脂、石油增粘树脂,包括C5/C9烃树脂;天然橡胶或合成橡胶如苯乙烯和丁二烯共聚物(SBR)、聚异丁烯(PIB)、聚异戊二烯(IR)、异丁烯与异戊二烯的共聚物、氯丁橡胶、丙烯腈丁二烯共聚物、乙烯丙烯橡胶、聚氨酯橡胶、氯化聚乙烯及其混合物。
在可用于合成聚合物颗粒16的材料中,更优选的是丙烯酸酯均聚物或共聚物、丙烯酸酯均聚物或共聚物和聚乙酸乙烯酯。特别优选的材料是聚甲基丙烯酸甲酯(PMMA)。
因此,在优选实施方案中,该膜包括具有两个主面的载体片层(例如聚乙烯膜);紧贴载体片层的主面附着的防水胶粘层(例如合成聚合物如SIS、SEBS或SEPS);和紧贴防水胶粘层布置或部分嵌入防水胶粘层中的包含具有100至600 µm的平均直径并具有圆形的聚甲基丙烯酸甲酯(PMMA)颗粒的粒子层,所述颗粒通过悬浮聚合形成。更优选地,该颗粒由PMMA、聚乙酸乙烯酯或其混合物制成;且防水胶粘剂由SIS制成。
在进一步的示例性实施方案中,本发明中的聚合物或有机粒子层可进一步含有一种或多种添加剂,如抗氧化剂、热稳定剂、光稳定剂、阻燃剂、填料、增塑剂、交联剂、抗静电剂、偶联剂、颜料、粘度改进剂或其它添加剂。
本发明的进一步示例性的粒子层包含聚合物粒子与无机粒子的混合物。无机粒子包含一种或多种材料,如部分水化水泥、水化水泥、碳酸钙、硅酸盐砂、砂、非晶二氧化硅、矿渣、三水合氧化铝、底灰、板岩灰、花岗岩灰等。无机粒子也可根据所需性质使用一种或多种化学外加剂制备。所用的各种外加剂可包括常规用于实现下列性质的那些:(1)增强膜与混凝土的粘结;(2)加速初凝时间;(3)加速在(水泥固化或硬化)早期的强度发展速率;(4)提高成品材料的强度(压缩、拉伸或弯曲);(5)减少材料内的水的毛细流动;(6)降低材料的液体渗透率;和/或(7)抑制嵌入的金属的腐蚀,如用于保护混凝土基质内的钢筋条或其它结构。
本发明的进一步示例性的粒子层包含聚合物/无机杂化粒子,如聚合物涂布或处理的无机粒子。
在进一步的示例性实施方案中,合成聚合物粒子可通过在任何上述无机材料上涂布任何上述聚合物形成。例如,可以用例如丙烯酸酯聚合物或共聚物、聚乙酸乙烯酯(PVA)聚合物或共聚物或其组合涂布碳酸钙、砂、白水泥或其它无机粒子。
如上所述,聚合物粒子(或聚合物/无机混合或杂化粒子)层的使用与使用无机粒子的现有技术方法相比也表明在独自使用细部处理或防水胶带(或条)(优选不额外使用液体底漆、玛𤧛脂(mastic)或其它液体涂料)将在施加现场边缘搭接的相邻铺设的膜密封在一起时获得的益处。可以高得多的可靠度和速度实现由两个或更多个本发明的防水膜形成的一体屏障的建立,仅使用细部处理或防水胶带。
常规防水、细部处理或连接胶带(或条状膜),如Grace Construction Products出售的那些(参见例如PV100™胶带、BITUTHENE®胶带)可用于将相邻片膜密封在一起。许多防水制造商出售防水胶带,并且这些胶粘剂可由沥青质或合成聚合物防水胶粘剂制成,并可适用于本发明。优选地,防水胶带是双面的,载体膜或织物的两面都带有预制防水压敏胶粘层,以使其可插在相邻膜的搭接边缘之间而不需要纵向折叠胶带。
在本发明的进一步的示例性实施方案中,沿着膜的侧边可基本不含颗粒材料,以更方便地沿膜边缘使用条状离型衬纸。可在铺设现场除去条状离型衬纸,以可暴露出压敏胶粘层并将其直接附着到载体膜的背面,由此可沿相邻边缘接合相邻膜。因此,在本发明的示例性实施方案中,沿膜的侧边的压敏胶粘层部分不含合成聚合物粒子,并使用条状离型衬纸防止胶粘剂在卷绕膜时粘到载体膜上;而膜的中心部分不需要任何离型衬纸,因为合成聚合物粒子允许膜卷绕以使胶粘剂不会粘到载体片上并妨碍在铺设现场展开膜。
本发明的防水膜的各种示例性实施方案可与可除去的离型衬纸一起使用以在膜的中心或中间部分或膜的整个从一边到另一边的宽度上进一步保护压敏胶粘层。或者,本发明的示例性膜可不含离型衬纸或仅沿膜的侧边包含条状离型衬纸。这取决于膜设计师或客户的偏好。例如,设计师或客户可能想要在外颗粒聚合物层上使用强力(aggressive)防滑涂层,并可能想要使用离型衬纸保护膜的整个胶粘剂/颗粒面。另一方面,该膜也有可能“无纸”并完全不使用离型衬纸或仅沿膜的边缘使用离型衬条(如果在边缘处没有使用颗粒,以利于膜的卷绕和展开)。
尽管在本文中使用有限数量的实施方案描述本发明,但这些具体实施方案无意限制如本文中以其它方式描述和要求保护的发明范围。存在对所述实施方案的修改和变动。更具体地,作为所要求保护的本发明的实施方案的具体举例说明给出下列实施例。应该理解的是,本发明不限于实施例中给出的具体细节。除非另行规定,实施例中以及说明书下文中的所有份数和百分比按重量百分比计。
此外,说明书或权利要求书中列举的任何数值范围,如代表一组特定的性质、测量单位、条件、物理状态或百分比的范围旨在照字面特此作为参考包含落在这样的范围内的任何数值,包括如此列举的任何范围内的数值的任何子集。例如,只要公开了具有下限RL和上限RU的数值范围,则具体公开了落在该范围内的任何数值R。特别地,具体公开了该范围内的下列数值R:R = RL + k*(RU -RL),其中k是1%至100%的以1%为增量的变量,例如k是1%、2%、3%、4%、5%. … 50%、51%、52%. … 95%、96%、97%、98%、99%或100%。此外,也具体公开了由如上计算的任何两个R值表示的任何数值范围。
本发明提供制造防水膜的示例性方法。胶粘剂可使用辊涂布机、缝模涂布机或帘流涂布机热熔涂布到载体上。也可用载体/胶粘剂层压材料(12/14)开始并在PSA变热(thermally hot)并软化的同时将聚合物或聚合物/无机混合或杂化粒子体16嵌入PSA层14中以产生聚合物粒子层16。应该使用重力、真空、刷掠或其组合从粒子层16上除去松散粒子,并将具有或不具有可除去的离型纸的所得防水膜卷绕成卷。
实施例1
可以通过用合成压敏(PSA)胶粘剂如SEBS、SBS、SIS、SBR等(其用于制造PSA层)的10密耳厚的涂层涂布例如载体片,如30密耳高密度聚乙烯(HDPE),制造本发明的一种示例性的防水膜。包含SIS聚合物的PSA是优选的。在此将具有180至830微米的平均粒度的聚(甲基丙烯酸甲酯)粒子用于粒子层。体积平均粒度是467 µm。来自Malvern Instruments的Mastersizer® 2000激光衍射粒度分析仪用于粒度分析测量。
将胶粘剂涂布的片材在空气循环烘箱中在70℃下放置1小时以软化PSA层,然后通过使用压力辊将细聚合物粒子嵌入PSA中而在PSA层的面上产生细聚合物粒子层。
然后将该膜放回烘箱中大约30分钟,并在PSA层的面上散布更多细粒子并再使用压力辊将粒子嵌入PSA层的面中以确保细粒物质在PSA层上的良好覆盖。可通过轻刷除去过量松散粒子。
通过遵循这样的方法,制造包括HDPE载体片(12)、防水压敏胶粘剂(14)、细聚合物粒子层(16)的三层防水膜。可如下使用对防水膜的各种测试程序。
测试与后施加的混凝土的粘结. 由于防水膜在膜上后施加混凝土之前通常暴露于太阳光,非常希望这样的膜在这样的暴露后保持它们充分附着至混凝土的能力。通过在1.5英寸 x 6英寸(3.8cm x 15cm)膜样品的外表面上浇注混凝土、允许混凝土固化7天、然后用Instron™机械测试机在180°的剥离角和4英寸(100mm)/分钟的剥离速率下测量剥离附着力,测试膜对混凝土的附着力。对没有暴露于紫外线辐射的样品(初始)和在浇注混凝土之前暴露于紫外线辐射的样品测量与混凝土的粘结强度,其中紫外线暴露使用EMMAQUA加速测试,其中暴露对应于1个月UV暴露(28mj)或一个半月UV暴露(42mj)的等效量。
端头搭接粘结性能(初始粘结和长期水浸). 使用双面胶带粘结卷端头以形成连续防水。(如果纵向折叠,可使用单面胶带,但这在实际施工作业过程中需要额外时间并且较不优选)。膜的卷端头最少搭接75mm。施加双面胶带并将胶面固定在底膜的搭接区域上。牢固辊轧(roll)以确保完全粘合而没有褶皱或空隙。剥离双面胶带另一面的离型纸并将第二块膜施加到胶带上。牢固辊轧以确保完全粘合。使用T剥离测试测定在24小时固化后端头搭接的粘结性能,剥离速度是100 mm/min。将端头搭接粘结样品长期水浸(即1个月)以检查水是否渗入端头搭接并降低粘结性能。
测试防粘连性. 由于防水膜通常卷绕成卷,非常希望确保膜的一个表面不会牢固附着到膜的另一个表面上。否则,难以展开该卷。为了测试防粘连性,将30密耳 (0.75mm)HDPE膜层置于2.0 x 6.0英寸膜样品的外表面上,在其上放置3磅/平方英寸(psi)荷载;然后将这一组装件在烘箱中在65℃下放置1周。在冷却到室温后,使用Instron™机械测试机用4英寸/分钟的十字头速度通过T-剥离测试测试各样品。以磅/线性英寸(N/mm)测量粘连。
水浸测试. 由于防水膜在浇注混凝土后可能浸泡在水中,非常希望这样的膜在这样的水暴露后保持它们附着到混凝土上的能力。已经设计出一种示例性的严格测试以举例说明本发明的膜的出色性能。通过在尺寸为1.5英寸 x 6英寸(3.8cm x 15cm)的膜样品的外表面上浇注混凝土、允许混凝土固化7天、将这一膜/混凝土组装件在水中浸泡90天;然后用Instron™机械测试机在180°的剥离角和100mm/分钟的剥离速率下测量剥离附着力,测试防水膜对混凝土的附着力。水可能渗入该组装件的任何界面之间,包括混凝土/anti-submarining涂层界面、anti-submarining涂层/粒子界面或粒子/压敏胶粘剂界面。这一测试被认为严格,因为在膜的正常使用中,这些界面不会暴露于水渗透。
抗横向水迁移性测试. 抗横向水迁移性是防止水在有盲区的(blind side)防水系统和混凝土结构之间移动。如果防水系统在混凝土浇注之前或过程中被钢筋或其它造成撕裂或空隙的尖锐物刺穿,水可能穿过防水系统。如果水在防水膜系统与混凝土之间自由地横向迁移,则其将会找到进入建筑物的途径。防止防水膜和地基之间的横向水迁移的防水系统对建筑物内部保持干燥是必需的。在样品中心制备1个10 mm直径的孔以模拟防水膜的缺口。将混凝土浇注到膜上并在静水压头压力测试前允许固化7天。压力保持在58磅/平方英寸(psi)24小时(h),然后在72 psi 4小时,在87 psi 4小时。横向水迁移测试结果报道为[合格/失败];合格被定义为实现极限压力步骤;失败被定义为水经试样漏出或在膜与混凝土之间存在水。
热老化测试: 将三个100mm x 50mm膜样品垂直悬挂在保持在70℃温度的烘箱中2小时,样品之间的最小间距大于30mm。在测试后,取出样品并观察在膜样品上是否发生任何滑动、垂挂或滴落。
对本发明的示例性防水膜的各种测试的结果显示在下表1中。
表1
示例性的防水膜表现出优异的与混凝土的初始粘结、在UV暴露后与混凝土的粘结和在水浸3个月后良好保持与混凝土的粘结。示例性的防水膜表现出良好的端头搭接粘结强度和在水浸1周后保持端头搭接粘结。剥离在水浸后的端头搭接粘结样品且界面干燥。示例性的防水膜表现出优异的高温稳定性并且在0.6MPa水渗透测试后没有水渗透。
在上文的说明书中阐述了本发明的原理、优选实施方案和操作模式。本发明不限于所公开的特定形式,因为这些被认为是示例性而非限制性的。技术人员可作出变动和修改而不背离本发明的精神。
Claims (21)
1.防水膜,包括:具有两个主面的载体片层;紧贴所述载体片层的主面附着的防水胶粘层;和紧贴所述防水胶粘层布置或部分嵌入所述防水胶粘层中的包含合成聚合物颗粒的粒子层。
2.权利要求1的防水膜,其中所述防水膜的防水胶粘层的总面积的25%至100%被所述合成聚合物颗粒覆盖。
3.权利要求1的防水膜,其中所述防水胶粘层的总面积的45%至100%被所述合成聚合物颗粒覆盖。
4.权利要求1的防水膜,其中所述防水胶粘层的总面积的65%至100%被所述合成聚合物颗粒覆盖。
5.权利要求1的防水膜,其中所述合成聚合物颗粒由选自聚烯烃(例如聚乙烯、聚丙烯或其混合物)、聚环氧乙烷、聚丙二醇、聚乙酸乙烯酯、乙烯-乙酸乙烯酯共聚物、丙烯酸均聚物或共聚物、丙烯酸酯均聚物或共聚物、丙烯酸/丙烯酸酯共聚物、烯烃/丙烯酸共聚物、烯烃/丙烯酸酯共聚物、马来酸酐/丙烯酸共聚物、苯乙烯共聚物如苯乙烯/丙烯酸系共聚物和苯乙烯/丙烯酸酯共聚物、马来酸酐共聚物如苯乙烯/马来酸酐共聚物、马来酸酐/烯烃共聚物、乙酸乙烯酯/马来酸酐共聚物;增粘树脂如松香树脂或改性松香树脂、萜烯树脂或改性萜烯树脂、石油增粘树脂,包括C5/C9烃树脂;天然橡胶或合成橡胶如苯乙烯和丁二烯共聚物(SBR)、聚异丁烯(PIB)、聚异戊二烯(IR)、异丁烯与异戊二烯的共聚物、氯丁橡胶、丙烯腈丁二烯共聚物、乙烯丙烯橡胶、聚氨酯橡胶、氯化聚乙烯或上述聚合物的组合的聚合物制成。
6.权利要求1的防水膜,其中所述合成聚合物颗粒由选自聚乙酸乙烯酯、丙烯酸酯、聚苯乙烯和苯乙烯共聚物的聚合物制成。
7.权利要求6的防水膜,其中所述合成聚合物颗粒通过悬浮聚合形成。
8.权利要求1的防水膜,其中所述合成聚合物颗粒包含聚甲基丙烯酸甲酯共聚物,并且进一步其中所述防水胶粘剂包含苯乙烯-异戊二烯-苯乙烯嵌段共聚物。
9.权利要求1的防水膜,其中所述合成聚合物颗粒包含聚乙酸乙烯酯共聚物,并且进一步其中所述防水胶粘剂包含苯乙烯-异戊二烯-苯乙烯嵌段共聚物。
10.权利要求1的防水膜,其中所述合成聚合物颗粒具有100至600 µm的平均直径。
11.权利要求1的防水膜,其中所述合成聚合物颗粒通过用合成聚合物材料涂布无机粒子形成。
12.权利要求1的防水膜,其中所述合成聚合物颗粒通过将由合成聚合物制成的制品研磨成较小尺寸的粒子形成。
13.权利要求1的防水膜,其中所述合成聚合物颗粒具有球形形状。
14.权利要求1的防水膜,其进一步包括紧贴所述防水胶粘层布置的保护涂层或在合成颗粒层上的保护涂层。
15.权利要求1的防水膜,其中所述防水胶粘层和载体层沿膜的侧边延伸超出合成聚合物颗粒的粒子层;所述膜进一步具有附着于所述防水胶粘层的可除去的离型衬条以使所述膜可卷绕和展开而在卷绕膜时所述防水胶粘层不会粘到载体层的背面。
16.防水膜,包括:具有两个主面的载体片层;紧贴所述载体片层的主面附着的防水胶粘层;和紧贴所述防水胶粘层布置或部分嵌入所述防水胶粘层中的包含合成聚合物颗粒的粒子层,所述合成聚合物颗粒包含聚甲基丙烯酸甲酯,所述聚合物颗粒具有100至600 µm的平均直径并具有圆形形状。
17.权利要求16的防水膜,其中所述聚合物颗粒通过悬浮聚合形成。
18.权利要求16的防水膜,其中所述合成聚合物颗粒通过在无机材料上涂布聚合物形成。
19.权利要求16的防水膜,其中沿所述膜的侧边的压敏胶粘剂部分不含所述合成聚合物颗粒,并使用条状离型衬纸防止胶粘剂在卷绕膜时粘到载体膜上。
20.包括将混凝土浇注在权利要求1的膜的包含合成聚合物颗粒的粒子层上的方法。
21.防水组装件,包括浇注在权利要求1的膜的包含合成聚合物颗粒的粒子层上的混凝土。
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