TWI691579B - 具粒狀高分子外保護層之預塗膜 - Google Patents

具粒狀高分子外保護層之預塗膜 Download PDF

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Publication number
TWI691579B
TWI691579B TW107138917A TW107138917A TWI691579B TW I691579 B TWI691579 B TW I691579B TW 107138917 A TW107138917 A TW 107138917A TW 107138917 A TW107138917 A TW 107138917A TW I691579 B TWI691579 B TW I691579B
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Taiwan
Prior art keywords
waterproof
copolymer
polymer particles
layer
synthetic polymer
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TW107138917A
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English (en)
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TW201922998A (zh
Inventor
陳呼和
丁紅梅
羅伯特 Ａ 威爾辛斯基
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美商Ｇｃｐ應用科技公司
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    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
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Abstract

本發明提供一種預塗防水膜，其具有防水黏著層及外粒子層，該外粒子層包含合成高分子顆粒以保護該黏著層且有助於膜與膜重疊部處之細節處理。在較佳實施例中，該等合成高分子顆粒由選自由以下組成之群之高分子製得：聚乙酸乙烯酯、丙烯酸及苯乙烯丁二烯共聚物或高分子。最佳地，該等合成高分子顆粒之形狀為圓形或球形，該等形狀有助於在建築或安裝場所處進行細節處理，諸如在膜重疊部處密封及圍繞管道或其他細節密封。或者，該等膜可製備成具有不含合成高分子顆粒之側邊緣，其中可移除剝離襯墊條可用於在該膜自身捲起以便裝運時防止黏著劑黏附至該膜之背面。

Description

具粒狀高分子外保護層之預塗膜
本發明係關於自黏著防水膜，且更特定言之，係關於一種預塗防水膜，該膜具有防水黏著層及外粒子層，該外粒子層包含合成高分子顆粒以保護該黏著層且有助於膜與膜重疊部處之細節處理(detailing)。
在美國專利5,496,615 (由本發明共同受讓人擁有)中，Bartlett等人首先教示「預塗」防水膜之用途，該等膜包含載體層、黏著層及保護塗佈層。膜安置成載體層側抵靠模具或模板，其中黏著層及保護塗佈層面朝外，以使得可將混凝土向其澆鑄且在使混凝土固化及硬化時與其黏結。
'615專利描述安置於保護塗佈層上之一層細微粉碎粒子材料的用途，其用於降低黏著層及保護塗佈層之黏性，使得可容許在膜上步行通過，而不會破壞黏著層及保護塗佈層與後澆鑄混凝土黏結之能力(參見第2欄，第52-57行)。Bartlett等人教示此類粒子材料可包含較佳粒度範圍為約0.1至1000微米之碳酸鈣、砂、矽酸鹽砂、水泥或滑石(參見第7欄，第50-61行)。此等無機粒子中較佳為碳酸鈣及砂，因為其顯然提供與混凝土之良好黏結能力，混凝土隨後向該等粒子澆鑄(「後澆鑄」)。
在美國專利6,500,520 (由本發明共同受讓人擁有)中，Wiercinski等人教示預塗防水膜，其中無機粒子與由水合混凝土產生之氫氧化物反應，形成水合產物。此等反應性無機粒子包括三水合氧化鋁、二氧化矽、飛灰、高爐爐渣、矽石煙及鹼金屬鹽或鹼土金屬鹽。Wiercinski等人教示粒子可包括火山灰或火山灰質材料之使用，包括矽藻土、石灰石、黏土(例如偏高嶺土)及葉岩，以及飛灰及高爐爐渣。火山灰，諸如矽質或鋁矽質材料，本身具有低膠結值或不具有膠結值(亦即，作為黏合劑材料)。然而，此類材料呈細微粉碎形式時可與由水合水泥釋放之氫氧化鈣化學反應，形成具有膠結特性之材料，由此促成在潮濕混凝土向預塗膜後澆鑄時的黏結強度(第3欄，第57-67行)。
在美國專利8,453,405及8,713,879 (由本發明共同受讓人擁有)中，Wiercinski等人教示塗覆防水膜，其中無機粒子性質上為實質上反射性的。粒子較佳由研磨白水泥、研磨水合白水泥、研磨部分水合水泥或其混合物構成。此類反射性無機粒子之使用似乎改良膜與後澆鑄混凝土之間的黏結(參見例如第8欄，第26行等)。此外，膜不需要具有可移除剝離薄片，原本需要該薄片以防止當膜捲起時黏著劑黏附至載體薄片。
預塗防水膜設計之發展近年來以及在其歷史之大部分時間中聚焦於外層中之無機粒子材料。如上文所概述，此包括礦物、水泥、膠結物、火山灰及火山灰質材料，其皆賦予防水膜有用的功能。與保護塗佈層組合，此等功能包括保護防水黏著層免受降解、步行通過及機械影響，以及有助於與後澆鑄混凝土黏結及在不使用可移除剝離襯墊之情況下捲起/展開膜。
然而，對於諸位發明人而言，使用無機粒子增加在工地處進行細節處理之難度。無機粒子之此類使用增加將鄰近膜接合(或搭接)在一起之難度，且增加此操作所需的勞動及時間。導致堵塞之帶與無機材料之間的不相容性係諸位發明人試圖經由本發明解決的問題之一。
為克服先前技術之缺點，本發明提供一種新穎及創造性預塗防水膜，其具有具兩個主面之載體薄片層；抵靠該載體薄片層之一主面附著之防水黏著層；及包含合成(有機)高分子顆粒之粒子層。
諸位發明人咸信在外保護粒子層中使用合成(有機)高分子顆粒將有助於在工地處進行細節處理操作，特定言之將鄰近膜之邊緣搭接部接合或縫合在一起，以及有助於形成圍繞管道及模板、混凝土基礎及工地處之其他細節中之其他突起或凹陷的障壁保護件。
在較佳實施例中，防水膜之防水黏著層之總面積的25%至100%由有機高分子顆粒覆蓋；更佳地，防水黏著層之總面積的45%至100%由合成(有機)高分子顆粒覆蓋；且最佳地，防水黏著層之總面積的65%至100%由合成(有機)高分子顆粒覆蓋。
在替代性實施例中，預塗膜具有側邊緣，沿該側邊緣防水黏著層之一部分不含合成(有機)高分子顆粒，以使防水黏著層直接搭接至鄰近膜之載體薄片的背面上(且可將剝離襯墊條沿膜邊緣施加於壓敏黏著劑上方以允許將膜捲起，且其中在安裝時移除剝離襯墊條，使得可將暴露黏著劑黏附至載體層之背側，其中鄰近膜可縫合在一起)。
預期用於本發明之例示性顆粒包括選自聚乙酸乙烯酯、丙烯酸(例如PMMA)及聚苯乙烯及苯乙烯共聚物之合成(有機)高分子。在較佳實施例中，合成高分子顆粒經由懸浮聚合製備。
在另外的例示性實施例中，可藉由用高分子塗佈諸如碳酸鈣、砂或其他無機材料之無機粒子形成合成高分子顆粒。
本發明亦關於使用在外粒子層中具有有機高分子顆粒之上述膜用於防水基材及表面之方法。可將本發明之膜塗覆至各種基材，包括模具及支拱板條(lagging) (例如混凝土模板)，以及礫石、混凝土、土壤保持系統、壁及其他基材或表面。
儘管可視情況在外向合成高分子顆粒上使用保護塗佈層作為防水壓敏黏著劑(PSA)層之進一步保護，但諸位發明人咸信使用合成(有機)高分子顆粒可以在無視情況選用之保護塗層的情況下為防水PSA層提供足夠的保護。
在另外的例示性實施例中，可將塗料塗覆於合成高分子顆粒上、合成高分子顆粒之間或合成高分子顆粒上及合成高分子顆粒之間以為膜提供抗滑動性。
下文詳細描述另外的優點及特徵。
圖1示出本發明之例示性預塗防水膜10 ，其包含具有兩個主面之可撓性載體薄片層12；具有兩個主面之防水壓敏黏著層14，其中之一個主面附著至該等載體薄片層12主面中之一者；及在防水黏著層14外部之包含合成高分子顆粒之粒子層16。
在另外的例示性實施例中，可在粒子層16上方，或在防水黏著層14與粒子層16之間，或在粒子層16內之粒子之間或其組合使用視情況選用之保護塗佈層(未圖示)，以為防水黏著層14提供進一步保護。儘管諸位發明人咸信粒子層16可能足以保護防水黏著層14免受步行通過及磨損影響，但在粒子朝外之面上方及/或粒子(16)之間的視情況選用之保護塗層可帶來其他有幫助的特性，諸如提高的抗滑動性、UV保護或其他有益的特性。
圖2係描繪本發明之例示性防水膜之例示性合成高分子粒子(如圖1中16處所表示)的光學顯微鏡像片，其中高分子顆粒部分包埋於黏著層中。圖2之顯微鏡像片以50×放大率取得。顯而易見高分子顆粒提供安置膜時抵抗步行通過之凹凸不平的表面區域，以及特定抗結塊益處。儘管圖2中所示之圓形(略圓)或球形粒子對於實現此等特徵之目的而言係較佳的，但本發明不受限於此類圓形或球形，因為粒子層中之合成高分子顆粒可以採用任何種類之形狀，諸如不規則形狀，或粒子具有研磨或斷裂表面，該等表面由將高分子材料機械研磨至較小粒度產生。
預期用於本發明之例示性載體薄片層12可由熱塑性塑膠、橡膠或呈連續膜形式之金屬、編織材料、玻璃、或非編織材料製成。尤其適用於本發明之熱塑性塑膠包括聚丙烯、聚乙烯、乙烯-丙烯共聚物、聚苯乙烯(PS)、乙烯-烯烴共聚物、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)、聚對苯二甲酸伸乙酯(PET)、聚氯乙烯(PVC)、聚醯胺及其組合。
較佳載體薄片層12包含高密度聚乙烯(HDPE)之熱塑性膜。織物可以係編織或非編織的，且可包含聚乙烯、聚丙烯、聚對苯二甲酸伸乙酯及聚醯胺。編織聚丙烯織物亦尤其適合。可撓性載體層12可包含層合物，該層合物包含兩個或更多個熱塑性塑膠、橡膠或呈連續膜形式之金屬、編織材料、玻璃、或非編織材料的薄片。可撓性載體層12亦可為共擠出多層膜或薄片，或為連續膜、編織材料或非編織材料。
適用於本發明之例示性可撓性載體薄片層12材料應為預塗防水膜10之結構提供機械強度及防水完整性。載體層12應較佳具有約0.05至2.0 mm、且更佳約0.3至1.0 mm之厚度。載體層12應進一步具有大體上光滑的表面，該表面諸如由膜、薄片、織物及擠出塗佈編織物或非編織物提供。
一般而言，載體層或薄片12不經提高表面張力之表面處理。然而，在一些情況下可能處理黏著劑14將塗覆於其上之載體薄片12之表面為宜，以便增強黏著層14與載體薄片12之黏著力。表面處理之實例為電暈處理。
可將添加劑併入至載體層12材料中。載體層12可含有諸如以下之添加劑中之一或多者：抗氧化劑、熱穩定劑、光穩定劑、阻燃劑、填充劑、塑化劑、抗靜電劑、顏料、加工助劑、抗生根劑、抗微生物劑等。可將此等在獨立混配步驟中併入至材料主體中。亦可在熔融擠壓程序期間將添加劑併入至材料主體中以製造薄片、膜或擠出塗佈織物。
最適用於本發明之例示性防水黏著層14應為膜10提供防水完整性。防水黏著層14部分或完全地起作用以將粒子層16黏結至載體薄片12。本發明中可採用煙煤或橡膠改質煙煤黏著劑。為了改良在應用工地處UV曝光之後與後澆鑄混凝土之黏著力，基於合成高分子之防水黏著劑14係更佳的。黏著層14較佳具有如根據ASTM D 5-73量測之大於約30絲米(decimillimeter；dmm) (150 g，5秒，70℉)之滲透。
如本文所使用，術語「基於合成高分子之防水黏著劑」係指用於防水黏著層(如圖1中14處所表示)之非煙煤或非瀝青黏著劑。本發明之例示性非煙煤或合成黏著層包括基於丁基橡膠之黏著劑、基於聚異丁烯之黏著劑、基於聚異丁基之黏著劑、基於丙烯酸之黏著劑、基於苯乙烯-異戊二烯-苯乙烯(SIS)之黏著劑、基於苯乙烯-乙烯-丙烯-苯乙烯(SEPS)之黏著劑、基於苯乙烯-丁二烯-苯乙烯(SBS)之黏著劑、基於苯乙烯-乙烯-丁烯-苯乙烯(SEBS)之黏著劑、基於苯乙烯-丁二烯橡膠(SBR)之黏著劑及其組合。較佳為壓敏黏著劑(PSA)。較佳地，合成黏著劑為SIS、SBS、SEBS或SEPS及其組合之壓敏熱熔黏著劑嵌段共聚物。為獲得壓敏黏著劑之更詳細描述，參見Satas,Handbook Of Pressure Sensitive Adhesive Technology , (Van Nostrand Reinhold Company, Inc., 1982)。基於黏著層之合成高分子應較佳具有約3至30密耳、更佳約5至15密耳且最佳約8至10密耳之厚度。
此外，適用於黏著層14之橡膠或彈性體包括聚胺基甲酸酯、聚異戊二烯、聚丁二烯、天然橡膠、聚氯丁二烯橡膠、乙烯-丙烯橡膠、乙烯α烯烴、腈橡膠、丙烯酸橡膠或其混合物。
另外的例示性黏著層14包括一或多種非晶系聚烯烴。非晶系聚烯烴(APO)定義為如藉由差示掃描量熱法所量測結晶度小於30%之聚烯烴。此等高分子可為丙烯均聚物或丙烯與一或多種α-烯烴共聚單體(諸如乙烯、1-丁烯、1-己烯、1-辛烯及1-癸烯)之共聚物。如基於橡膠之黏著劑，高分子亦與增黏劑及塑化劑組合以產生PSA組合物，該PSA組合物可塗佈至載體層12上。參見例如Eastman公報「Pressure-Sensitive Adhesives Based on Amorphous Polyolefin From Eastman Chemical Company」。
儘管不較佳，但亦可將包括經橡膠及/或其他添加劑改質之組合物的煙煤PSA材料塗佈至載體層或薄片上。煙煤或橡膠改質煙煤黏著層應較佳具有10至200密耳之厚度。
本發明中之防水黏著層14可視情況含有防水膜中通常所使用之添加劑，該等添加劑包括(但不限於)光吸收劑(例如碳黑、苯并三唑等)、光穩定劑(例如受阻胺、二苯基酮)、抗氧化劑(例如受阻酚)、填充劑(例如碳酸鈣、二氧化矽、二氧化鈦等)、塑化劑、流變添加劑及其混合物。較佳組合為包含光吸收劑、光穩定劑、抗氧化劑或其混合物之合成PSA。在本發明另外的例示性實施例中，高分子粒子層16亦可包括此等視情況選用之添加劑中之一者。
本發明中之黏著層14可視情況含有熱塑性塑膠、橡膠或呈連續膜形式之金屬、編織材料、玻璃或非編織材料之強化層。
如先前所提及，出於對防水黏著層之額外保護或其他目的(諸如為獲得可通行性(trafficability)而增加之摩擦力、抗滑動性等)，本發明之例示性防水膜可視情況包含諸如抵靠外粒子層(16)塗覆之保護塗佈層(圖1或2中未示出）。保護塗佈層揭示於先前技術部分中所論述之大量先前技術參考文獻中。然而，諸位發明人咸信在外粒子層(16)中使用合成(有機)高分子顆粒提供一種保護態樣，其出人意料地在很大程度上避免過去對保護塗佈層之依賴，且此為本發明另外的益處。
最後，如先前論述，在防水黏著層14上方形成包含合成高分子顆粒(視情況具有如先前技術部分之先前論述中所提及之一或多種無機粒子)之粒子層16。含高分子顆粒之粒子層16可有效保護黏著層14免受粉塵、污跡及元素(特定言之日光)影響。較佳地，粒子層16內之有機高分子顆粒具有1 µm至1000 µm之平均直徑；且更佳地，約100 µm至600 µm之平均直徑。經由雷射繞射技術量測平均粒徑。按等效體積球體直徑量測粒度。適合市售設備可購自Malvern，且以商品名Mastersizer™ 2000及Mastersizer™ 3000銷售。藉由將視情況具有無機粒子(例如白水泥、三水合鋁等)之合成高分子顆粒部分嵌入至黏著層14之第二主面(與附著至載體層12之主面相對)形成粒子層16，其中粒子體16之一部分相對於黏著層14保持不浸沒。
在另外的例示性實施例中，粒子層16之塗層重量較佳為每平方公尺100至700公克；且更佳地，粒子層之塗層重量為每平方公尺200至400公克。
在安裝期間粒子層16形成與後澆鑄混凝土之機械互鎖，形成與所得結構之強黏結，提高膜10之抗滑動性，且提高膜10之通過能力(對步行通過之耐久性)。
粒子之形狀可以係規則或不規則的。球形粒子將視為具有規則形狀。可藉由懸浮聚合製備此類高分子粒子。或者，粒子可具有不規則形狀。舉例而言，可藉由製造不規則形狀粒子之各種研磨方法產生粒子。
用於形成合成高分子顆粒之合成高分子材料可選自有機高分子，包括(但不限於)聚烯烴(例如聚乙烯、聚丙烯或其混合物)、聚環氧乙烷、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、烯烴/丙烯酸共聚物、烯烴/丙烯酸酯共聚物、順丁烯二酸酐/丙烯酸共聚物、苯乙烯共聚物(諸如苯乙烯/丙烯酸共聚物及苯乙烯/丙烯酸酯共聚物)、順丁烯二酸酐共聚物(諸如苯乙烯/順丁烯二酸酐共聚物、順丁烯二酸酐/烯烴共聚物、乙酸乙烯酯/順丁烯二酸酐共聚物)；增黏樹脂，諸如松香樹脂或經改質松香樹脂、萜烯樹脂或經改質萜烯樹脂、石油增黏樹脂(包括C5/C9烴樹脂)；天然橡膠或合成橡膠，諸如苯乙烯及丁二烯共聚物(SBR)、聚異丁烯(PIB)、聚異戊二烯(IR)、異丁烯與異戊二烯之共聚物、氯丁橡膠、丙烯腈丁二烯共聚物、乙烯丙烯橡膠、聚胺基甲酸酯橡膠、氯化聚乙烯及其混合物。
適用於合成高分子顆粒16之材料中更佳為丙烯酸酯均聚物或共聚物、丙烯酸酯均聚物或共聚物及聚乙酸乙烯酯。尤佳材料為聚甲基丙烯酸甲酯(PMMA)。
因此，在較佳實施例中，膜包含載體薄片層(例如聚乙烯膜)，其具有兩個主面；防水黏著層(例如合成高分子，諸如SIS、SEBS或SEPS)，其抵靠載體薄片層之一個主面附著；及抵靠防水黏著層安置或部分嵌入防水黏著層內之粒子層，其包含平均直徑為100至600 µm且形狀為圓形(略圓)之聚甲基丙烯酸甲酯(PMMA)顆粒，該等顆粒經由懸浮聚合形成。更佳地，顆粒由PMMA、聚乙酸乙烯酯或其混合物製成；且防水黏著劑由SIS製成。
在另外的例示性實施例中，本發明中之高分子或有機粒子層可進一步含有一或多種添加劑，諸如抗氧化劑、熱穩定劑、光穩定劑、阻燃劑、填充劑、塑化劑、交聯劑、抗靜電劑、偶合劑、顏料、黏度調節劑或其他添加劑。
本發明另外的例示性粒子層包含高分子粒子與無機粒子之混合物。無機粒子包含一或多種材料，諸如部分水合水泥、水合水泥、碳酸鈣、矽酸鹽砂、砂、非晶形二氧化矽、爐渣、三水合氧化鋁、底灰、板岩粉、花崗石粉及其類似物。亦可使用化學摻合物或視所要特性而定之摻合物製備無機粒子。所使用之各種摻合物可包含習知地用於實現以下特性之彼等摻合物：(1)增強膜與混凝土之黏結；(2)加快初始凝固時間；(3)加快(水泥固化或硬化)早期階段強度發展；(4)增加成品材料之強度(壓縮、拉伸或撓曲)；(5)降低水在材料內之毛細流動；(6)降低材料之液體滲透率；及/或(7)抑制嵌入金屬之腐蝕，諸如用於保護混凝土基質內之鋼筋。
本發明另外的例示性粒子層包含高分子/無機混雜粒子，諸如經高分子塗佈或處理之無機粒子。
在另外的例示性實施例中，可藉由在前述無機材料中之任一者上塗佈前述高分子中之任一者形成合成高分子粒子。舉例而言，可以用例如丙烯酸酯高分子或共聚物、聚乙酸乙烯酯(PVA)高分子或共聚物或其組合塗佈碳酸鈣、砂、白水泥或其他無機粒子。
如先前所描述，與使用無機粒子之先前技術方法相比，使用高分子粒子層(或高分子/無機混雜或混合粒子)亦表明較佳在不另外使用液體底塗劑、膠或其他液體塗層材料之情況下，在在施加位置處單獨使用細節處理或防水帶(或條)將在邊緣重疊之鄰近安置的膜密封在一起時獲得益處。可以更高信賴度及速度實現僅使用細節處理或防水帶由本發明之兩種或更多種防水膜形成之單塊障壁的創建。
習知防水、細節處理或接合帶(或剝離膜)可用於將鄰近薄片膜密封在一起，該等諸薄片膜如由Grace Construction Products銷售(參見例如PV100™帶、BITUTHENE® 帶)。許多防水製造商出售防水帶，且此等黏著劑可由煙煤或合成高分子防水黏著劑製成，且將適用於本發明。較佳地，防水帶為雙側的，此係因為載體膜或織物之兩側攜有預成防水壓敏黏著層，使得可將其插入在鄰近膜之重疊邊緣之間而無需將帶縱長摺疊。
在本發明另外的例示性實施例中，沿膜之側邊緣可以實質上不含粒狀材料，使得沿膜邊緣使用剝離襯墊條較方便。可在安裝位置移除剝離襯墊條，使得壓敏黏著層暴露且與載劑膜之背側直接附著，其中鄰近膜可沿鄰近邊緣縫合在一起。因此，在本發明之例示性實施例中，沿膜之側邊緣的壓敏黏著層部分不含合成高分子粒子，且剝離襯墊條用於在膜捲起時防止黏著劑黏附至載體膜；而膜之中心部分不需要任何剝離襯墊，因為合成高分子粒子允許膜捲起，使得黏著劑不黏附至載體薄片且防止膜在安裝位置處展開。
可將本發明之防水膜的各種例示性實施例與可移除剝離襯墊一起使用，以在膜之中心或中部或膜之整個邊緣至邊緣寬度處進一步保護壓敏黏著層。或者，本發明之例示性膜可以不包含剝離襯墊或僅包含沿膜之側邊緣的剝離襯墊條。此將視膜設計者或客戶之偏好而定。舉例而言，設計者或客戶可能想要在外顆粒高分子層上使用積極性抗滑動塗層，且可能想要使用剝離襯墊以保護膜之整個黏著劑/顆粒側。另一方面，亦有可能為使膜「無紙」且完全不使用剝離襯墊或僅沿膜之邊緣使用剝離襯墊條(若邊緣處不使用顆粒，以有助於膜之捲起及展開)。
儘管在本文中使用有限數目個實施例描述本發明，但此等具體實施例並不意欲限制本文中以其他方式描述及主張之本發明的範疇。存在對所描述之實施例的修改及變化。更特定言之，提供以下實例作為所主張之本發明之實施例的具體說明。應瞭解本發明不限於實例中所闡述之具體細節。除非另外規定，否則實例中以及本說明書之剩餘部分中的所有份數及百分比按重量計。
另外，說明書或申請專利範圍中所敍述之諸如表示性質之特定集合、量測單位、條件、物理狀態或百分比之數字的任何範圍意欲照字面上以引用方式或以其它方式明確併入屬於此等範圍內之任何數字，包括如此敍述之任何範圍內之數字的任何子集。舉例而言，每當揭示具有下限RL和上限RU的數值範圍時，具體揭示屬於所述範圍內的任何數字。特定言之，具體揭示在範圍內之以下數字R：R = RL + k*(RU -RL)，其中k為在1%至100%範圍內增量為1%之變數，例如k為1%、2%、3%、4%、5% … 50%、51%、52% …95%、96%、97%、98%、99%或100%。此外，如上文所計算由R之任何兩個值表示的任一數值範圍亦經具體揭示。
本發明提供用於製造防水膜之例示性方法。可使用滾塗機、槽模塗佈機或簾式塗佈機將黏著劑熱熔塗佈至載體上。吾人亦可以載體/黏著劑層合物(12/14)開始，且在以熱方式將PSA加熱且軟化時將高分子或高分子/無機混合或混雜粒子體16嵌入至PSA層14以產生高分子粒子層16。應使用重力、真空、刷洗或其組合將鬆散粒子自粒子層16移除，且將所得防水膜捲繞成具有或不具有可移除剝離薄片的卷。
實例 1 可藉由用用於製備PSA層之合成壓敏(PSA)黏著劑(諸如SEBS、SBS、SIS、SBR等)之10密耳厚度塗層塗佈例如載體薄片(諸如30密耳高密度聚乙烯(HDPE)，產生本發明之例示性防水膜。較佳為包含SIS高分子之PSA。平均尺寸為180至830微米之聚(甲基丙烯酸甲酯)粒子在本文中用於粒子層。體積平均粒度為467 µm。使用來自Malvern Instruments之Mastersizer® 2000雷射繞射粒度分析器進行用於粒度分析之量測。
將經黏著劑塗佈之薄片置於70攝氏度之空氣循環烘箱中持續一小時以使PSA層軟化，且隨後藉由使用壓力輥將細微高分子粒子嵌入至PSA在PSA層之面上產生細微高分子粒子層。
隨後將膜置放回烘箱持續約30分鐘，且較多細微粒子分散在PSA層之面上，且再次使用壓力輥將粒子嵌入至PSA層之面中以保證細微粒子物質在PSA層上之良好覆蓋。可藉由輕緩刷洗移除過量鬆散粒子。
藉由遵循該方法，產生三層防水膜，其包含HDPE載體薄片(12)、防水壓敏黏著劑(14)、細微高分子粒子層(16)。可以在防水膜上如下使用各種測試程序。
測試與後塗覆混凝土之黏結 。 由於防水膜在向膜後塗覆混凝土之前通常經受日光曝露，特別需要此類膜在該曝露之後維持其完全黏著至混凝土之能力。藉由以下測試膜與混凝土之黏著力：向1.5吋×6吋(3.8 cm×15 cm)膜樣品之外面澆鑄混凝土，使混凝土固化七日，隨後用Instron™機械測試儀以180°剝離角度及4吋(100 mm)/分鐘之剝離速率量測剝離黏著力。在澆鑄混凝土之前對未曝露於UV輻射(初始)樣品及曝露於UV輻射之樣品量測與混凝土之黏結強度，其中UV曝露使用EMMAQUA加速測試，其中曝露對應於一個月UV曝露當量(28 mj)或一個半月UV曝露當量(42 mj)。
端搭接黏結效能 ( 初始黏結及長期浸水 ) 。 雙側帶用於黏結卷端，形成連續防水材料(若在縱長方向上摺疊，則可使用單側帶，但此需要實際建築工作期間的額外時間且不較佳)。膜之卷端以最小75 mm重疊。施加雙側帶且將黏著劑側固定在底部膜之重疊區域上。緊緊捲動以確保完全黏著而無折痕或空隙。將雙側帶之另一側的剝離型紙剝離，且將第2片膜施加至黏著帶。緊緊捲動以確保完全黏著。使用T剝離測試以測定在24 h固化之後端搭接部之黏結效能，剝離速度為100毫米/分鐘。將端搭接部黏結樣品長期浸水(亦即一個月)以檢查水是否將滲透進入端搭接部且降低黏結效能。
測試抗結塊性測試。 由於防水膜通常捲繞成卷，特別需要保證膜之一個表面不牢固地黏著於膜之另一表面。否則，將難以展開卷。為了測試抗結塊性，將一層30密耳(0.75 mm) HDPE膜置放於2.0×6.0吋膜樣品之外表面上，將3磅/平方吋(psi)負載置放於頂部上；隨後將此組合件置放於65攝氏度烘箱中持續1週。冷卻至室溫後，使用Instron™機械測試儀使用4吋/分鐘之十字頭速度用T剝離測試對各樣品進行測試。結塊量測為磅/線性吋(N/mm)。
浸水測試。 由於防水膜可能在向混凝土澆鑄之後浸沒在水中，因此特別需要此類膜在該水暴露之後維持其與混凝土黏著之能力。已設計極苛刻之測試以說明本發明之膜的優越效能。防水膜與混凝土之黏著力藉由以下測試：向尺寸為1.5吋×6吋(3.8 cm×15 cm)之膜樣品的外面澆鑄混凝土，使混凝土固化七日，將此膜/混凝土組合件浸沒在水中持續90日；且隨後用Instron™機械測試儀以180°之剝離角度及100毫米/分鐘之剝離速率量測剝離黏著力。水可滲入組合件之界面中之任一者，包括混凝土/抗下滑塗層界面、抗下滑塗層/粒子界面或粒子/壓敏黏著劑界面。此測試視為苛刻的，因為在膜之正常使用中，此等界面將不暴露於水滲入。
抗側向水移動性測試。 抗側向水移動性係對水在盲側防水系統與混凝土結構之間移動的防止。若在混凝土佈置之前或期間防水系統由鋼筋或其他尖銳物件刺穿，產生裂縫或空隙，則水可能通過該防水系統。若水在防水膜系統與混凝土之間自由側向行進，則其將找到進入建築之路徑。防止防水膜與基礎之間側向水移動之防水系統對保持建築內部乾燥而言係必需的。在樣品中心處製備一個10 mm直徑孔以模擬防水膜之裂口。將混凝土澆鑄至膜上，且在靜水頭壓力測試之前使其固化7日。將壓力保持在58磅/平方吋(psi)下持續24小時(h)，隨後在72 psi下4 h及在87 psi下4 h。側向水移動測試結果報告為[通過/失敗]；通過定義為實現極限壓力步驟時；失敗定義為水通過樣本向外漏泄或水存在於膜與混凝土之間。
熱老化測試 ： 將三個100 mm×50 mm膜樣品垂直懸掛在維持在70℃溫度下之烘箱中持續2小時，樣品之間的最小間距大於30 mm。在測試之後，取出樣品且觀測膜樣品上是否發生任何漏失、下陷或滴瀝。
在本發明之例示性防水膜上進行之各種測試的結果展示於下表1中。表 1
Figure 107138917-A0304-0001
例示性防水膜展現極佳的與混凝土之初始黏結、在UV曝露之後與混凝土之黏結及在浸水三個月之後對與混凝土黏結的良好保持。在浸水一週之後，例示性防水膜展示良好端搭接黏結強度及對端搭接黏結之保持。在浸水之後剝離端搭接黏結樣品且界面係乾燥的。例示性防水膜展現極佳高溫穩定性且在0.6 MPa水滲透測試之後未展現水滲透。
本發明之原理、較佳實施例及操作模式闡述於前述說明書中。本發明不限於所揭示之特定形式，因為此等形式視為說明性而非限制性的。熟習此項技術者可在不脫離本發明之精神的情況下作出變化及改變。
10‧‧‧預塗防水膜 12‧‧‧載體薄片層 14‧‧‧防水黏著層 16‧‧‧粒子層
當結合附圖考慮較佳實施例之以下實施方式時，可以更容易地瞭解本發明另外的優點及特徵，其中： 圖1係本發明之例示性預塗防水膜之橫截面的圖示(未按比例繪製)，該預塗防水膜包含載體薄片層、防水黏著層、粒子層，該粒子層抵靠以下安置、附著至以下或部分嵌入至以下：防水壓敏黏著層；且 圖2係由光學顯微鏡(以50×放大率)取得之本發明之另一例示性防水膜的顯微照片，該防水膜具有部分嵌入至防水壓敏黏著層之合成高分子粒子。

Claims (24)

  1. 一種防水膜，其包含：具有兩個主面之載體薄片層；抵靠該載體薄片層之一個主面附著之防水黏著層；及包含合成高分子顆粒之粒子層，該粒子層抵靠該防水黏著層安置或部分嵌入該防水黏著層內，其中該防水黏著層之總面積的65%至100%由該合成高分子顆粒所覆蓋。
  2. 如請求項1之防水膜，其中該等合成高分子顆粒由選自由以下組成之群的高分子製得：聚烯烴、聚環氧乙烷、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、苯乙烯共聚物、順丁烯二酸酐共聚物；增黏樹脂；天然橡膠或合成橡膠，或以上所提及之高分子之組合。
  3. 如請求項1之防水膜，其中該等合成高分子顆粒由選自由以下組成之群的高分子製得：聚乙酸乙烯酯、丙烯酸酯、聚苯乙烯及苯乙烯共聚物。
  4. 如請求項3之防水膜，其中該等合成高分子顆粒經由懸浮聚合形成。
  5. 如請求項1之防水膜，其中該等合成高分子顆粒包含聚甲基丙烯酸甲酯共聚物，且另外其中該防水黏著劑層包含苯乙烯-異戊二烯-苯乙烯嵌段共聚物。
  6. 如請求項1之防水膜，其中該等合成高分子顆粒包含聚乙酸乙烯酯共 聚物，且另外其中該防水黏著劑層包含苯乙烯-異戊二烯-苯乙烯嵌段共聚物。
  7. 如請求項1之防水膜，其中該等合成高分子顆粒之平均直徑為100μm至600μm。
  8. 如請求項1之防水膜，其中該等合成高分子顆粒藉由用合成高分子材料塗佈無機粒子形成。
  9. 如請求項1之防水膜，其中該等合成高分子顆粒藉由將由合成高分子製成之物品研磨成較小尺寸粒子形成。
  10. 如請求項1之防水膜，其中該等合成高分子顆粒之形狀為球形。
  11. 如請求項1之防水膜，其進一步包含抵靠該防水黏著層安置之保護塗佈層或在該合成粒子層上方安置之保護塗佈層。
  12. 如請求項1之防水膜，其中該防水黏著層及該載體薄片層沿該膜之側邊緣延伸超出該合成高分子顆粒之粒子層；該膜進一步具有附著至該防水黏著層之可移除剝離襯墊條，使得該膜可捲起及展開，而該膜捲起時該防水黏著層不會黏附至該載體薄片層之背面。
  13. 如請求項2之防水膜，其中該聚烯烴包含聚乙烯及/或聚丙烯。
  14. 如請求項2之防水膜，其中該丙烯酸均聚物或共聚物或丙烯酸酯均聚物或共聚物包含丙烯酸/丙烯酸酯共聚物、烯烴/丙烯酸共聚物、烯烴/丙烯酸酯共聚物、及/或順丁烯二酸酐/丙烯酸共聚物。
  15. 如請求項2之防水膜，其中該苯乙烯共聚物包含苯乙烯/丙烯酸共聚物及/或苯乙烯/丙烯酸酯共聚物。
  16. 如請求項2之防水膜，其中該順丁烯二酸酐共聚物包含苯乙烯/順丁烯二酸酐共聚物、順丁烯二酸酐/烯烴共聚物、及/或乙酸乙烯酯/順丁烯二酸酐共聚物。
  17. 如請求項2之防水膜，其中該增黏樹脂包含松香樹脂或經改質松香樹脂、萜烯樹脂或經改質萜烯樹脂、及/或包括C5/C9烴樹脂之石油增黏樹脂。
  18. 如請求項2之防水膜，其中該天然橡膠或合成橡膠包含苯乙烯及丁二烯共聚物(SBR)、聚異丁烯(PIB)、聚異戊二烯(IR)、異丁烯與異戊二烯之共聚物、氯丁橡膠、丙烯腈丁二烯共聚物、乙烯丙烯橡膠、聚胺基甲酸酯橡膠、及/或氯化聚乙烯。
  19. 一種防水膜，其包含：具有兩個主面之載體薄片層；抵靠該載體薄片層之一個主面附著之防水黏著層；及包含含有聚甲基丙烯酸甲酯之合成 高分子顆粒之粒子層，該粒子層抵靠該防水黏著層安置或部分嵌入該防水黏著層內，該等高分子顆粒之平均直徑為100μm至600μm且形狀為圓形。
  20. 如請求項19之防水膜，其中該等高分子顆粒經由懸浮聚合形成。
  21. 如請求項19之防水膜，其中該等合成高分子粒子藉由在無機材料上方塗佈高分子形成。
  22. 如請求項19之防水膜，其中沿該膜之側邊緣的壓敏黏著劑部分不含該等合成高分子粒子，且剝離襯墊條用於在該膜捲起時防止黏著劑黏附至該載體薄片層。
  23. 一種形成防水組合件之方法，其包含向如請求項1之膜之該包含合成高分子顆粒的粒子層澆鑄混凝土。
  24. 一種防水組合件，其包含向如請求項1之膜之該包含合成高分子顆粒之粒子層澆鑄的混凝土。
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