DESC:TECHNICAL FIELD OF THE INVENTION
[1] The present invention relates to a waterproofing membranes and more particularly to a waterproofing membrane having both uncoated sides and ends and a process for manufacturing thereof.
BACKGROUND OF THE INVENTION
[2] Waterproof membranes are essential components in various construction projects, including roofing, water tanks, and reservoirs, where protection against water ingress is critical. Typically, these membranes are laid down in overlapping layers and adjoin the adjacent waterproof membrane to create a continuous barrier that prevents water penetration. The waterproof sheets are joined by applying adhesive to the joint area of the waterproof sheet and adhering or by heat sealing as an alternative method. The heat sealing involves thermocompression bonding of the waterproof membranes at their side ends by overlapping and heating the overlapped end portions of the waterproof membranes.
[3] Generally, waterproofing membranes are manufactured by extruding and coating processes, resulting in continuous rolls of material. These membranes are often made of materials like sanded or gelled high-density polyethylene (HDPE), as shown in Figure 1. However, in construction of these membranes, creating end joints requires the removal of coating layers such as sand or gel, as well as the hot melt pressure sensitive adhesive (HMPSA) layer. This step of removal of coating layers complexity to the construction process, requiring more tools, time, and labor. Moreover, it may lead to weak end joints and premature termination of the HDPE-based waterproof membranes if the coating is not completely removed before the heat sealing operation.
[4] Accordingly, there is a need in the art for a waterproof membrane that has both uncoated sides and ends and a method for manufacturing thereof.
SUMMARY OF THE INVENTION
[5] The present invention provides a waterproofing membrane having both uncoated sides and ends and a process for manufacturing thereof.
[6] In one aspect, the present invention provides a process for manufacturing a waterproofing membrane, wherein the process comprising the steps of:
step 1 (S1) extruding at least one polymeric material to form a thin carrier sheet;
step 2 (S2) applying a tape on at least one side of the carrier sheet at a predefined interval along lateral direction;
step 3 (S3) coating a waterproofing pressure sensitive adhesive membrane on the at least one side of the carrier sheet along the longitudinal direction, wherein the waterproofing pressure sensitive adhesive membrane is coated on the at least one side of the carrier sheet having a width less than the actual width of the carrier sheet thereby leaving other sides uncoated; and
step 4 (S4) removing the tape to provide uncoated end at predefined interval to produce the waterproofing membrane having both uncoated sides and ends.
[7] In accordance with the embodiments of the present invention, the step (S1) of extruding the carrier sheet comprising the steps of:
i. pre heating an extrusion die head, a feeding barrel and an extrusion roll;
ii. drying the polymeric material at a predefined temperature to obtain a dried polymeric material;
iii. feeding the dried polymeric material to the preheated feeding barrel;
iv. transporting the molten polymeric material from the feeding barrel to extrusion die head via a melt pump; and
v. subjecting the extrusion die head for extruding a sheet to the calendaring rollers to obtain a roll of the carrier sheet.
[8] In accordance with the embodiments of the present invention, the step (S2) of applying tape is performed by a tape applicator having a contact roll that presses the tape against the at least one side of the carrier sheet of step 1 (S1).
[9] In accordance with the embodiments of the present invention, the tape is Polyethylene terephthalate (PET) tape with silicone adhesive.
[10] In accordance with the embodiments of the present invention, the tape applicator is a lap lock tape applicator.
[11] In accordance with the embodiments of the present invention, the step 3 (S3) of coating the waterproofing pressure sensitive adhesive membrane on the at least one side of the carrier sheet comprising the steps of:
i. obtaining the waterproofing pressure sensitive adhesive membrane materials comprising sand or gel and a hot melt pressure sensitive adhesive (HMPSA);
ii. storing the HMPSA and sand in a HMPSA tank and a sand tank respectively;
iii. pre-heating a coating die head, the HMPSA tank and the sand tank;
iv. adjusting a gap between the coating die head and the rollers based on thickness of the sheet to obtain the coating of a predetermined thickness;
v. loading the roll of the carrier sheet obtained in step 2 (S2) onto the unwinding section of the coating machine;
vi. locking the roll and joining the starting portion of the roll to the end portion of the previous roll sheet;
vii. maintaining the sheet edges within the marked guidelines using a plurality of sensors;
viii. setting desired roll length in the rewinding section panel; and
ix. pressing the die head onto the surface of the carrier sheet once the sheet starts moving to coat the carrier sheet such that sides of the carrier sheet are uncoated in the longitudinal direction and end of the carrier sheet is uncoated in the lateral direction to obtain the waterproofing membrane.
[12] In accordance with the embodiments of the present invention, the process for manufacturing a waterproofing membrane optionally comprises the step of coating a protective layer on the waterproofing pressure sensitive adhesive membrane. In an embodiment, the protective layer comprises a coating or dusting of finely divided inorganic particulate material on an outer exposed surface thereof.
[13] In accordance with the embodiments of the present invention, the waterproofing pressure sensitive adhesive membrane comprises materials like sand or gel and a hot melt pressure sensitive adhesive (HMPSA).
[14] In accordance with the embodiments of the present invention, the inorganic particulate material comprises at least one of sand, calcium carbonate, cement, and titanium dioxide dusted thereon.
[15] In accordance with the embodiments of the present invention, the process for manufacturing a waterproofing membrane optionally comprises the step of applying a substrate along and adjacent to one edge of the carrier sheet. In an embodiment, the substrate is a film or paper coated with a release agent on both surfaces and being removably adhered to either the pressure sensitive adhesive membrane or the protective layer.
[16] In accordance with the embodiments of the present invention, the film is selected from at least one of polyethylene, polypropylene, polyethylene terephthalate, and polyamide. In another embodiment, the release agent is silicone.
[17] In accordance with the embodiments of the present invention, the extrusion die head, the feeding barrel and the extrusion roll are preheated at a temperature in the range of 200 °C to 250 °C for a time period in the range of 2 hours to 5 hours.
[18] In accordance with the embodiments of the present invention, the polymeric material is selected from the group comprising of medium density polyethylene, linear low-density polyethylene.
[19] In accordance with the embodiments of the present invention, the carrier sheet optionally includes a roterproof material mixed with the polymeric material.
[20] In accordance with the embodiments of the present invention, the polymeric material is dried at the predefined temperature in the range of 90 °C to 120 °C.
[21] In accordance with the embodiments of the present invention, the coating die head, the HMPSA tank and the sand tank are pre-heated at the temperature in the range of 145 °C to 160 °C.
[22] In accordance with the embodiments of the present invention, the maximum coating has a width that is 200 mm less than the actual membrane width to ensure at least 100 mm width is retained at either side for heat sealing of the side laps.
[23] In accordance with the embodiments of the present invention, the tape has a width of 210 mm applied on the carrier sheet in the lateral direction at the predefined interval of 20 m.
[24] In another aspect, the present invention provides a waterproofing membrane comprising a thin carrier sheet having a removable tape adhered thereon, the removable tape is adhered on at least one side of the carrier sheet at a predefined interval along a lateral direction, and the at least one side of the carrier sheet having a waterproofing pressure sensitive adhesive membrane coated thereon, along the longitudinal direction thereby leaving uncoated sides therein.
[25] In accordance with the embodiments of the present invention, the width of the waterproofing pressure sensitive adhesive membrane coating on the at least one side of the carrier sheet is less than the actual width of the carrier sheet to form uncoated sides.
[26] In accordance with the embodiments of the present invention, the waterproofing membrane optionally comprises a protective layer coated on the waterproofing pressure sensitive adhesive membrane. The protective layer comprises a coating or dusting of finely divided inorganic particulate material on an outer exposed surface thereof.
[27] In accordance with the embodiments of the present invention, the waterproofing membrane optionally comprises a substrate along and adjacent one edge of the carrier sheet. In an embodiment, the substrate is a film or paper coated with a release agent on both surface and being removably adhered to either the pressure sensitive adhesive membrane or the protective layer.
[28] In accordance with the embodiments of the present invention, the release agent is silicone. In another embodiment, the film is selected from at least one of polyethylene, polypropylene, polyethylene terephthalate, and polyamide.
[29] In accordance with the embodiments of the present invention, the polymeric material is selected from the group comprising of medium density polyethylene, and linear low-density polyethylene.
[30] In accordance with the embodiments of the present invention, the carrier sheet optionally includes a roterproof material mixed with the polymeric material. In an embodiment, the roterproof material includes a micro-porous polymer filled with a plurality of bitter compounds and at least one UV compound. In another embodiment, the UV compound is Denatonium benzoate.
[31] In accordance with the embodiments of the present invention, the amount of medium density polyethylene is in the range of 70 wt.% to 100 wt.% of the total weight of the carrier sheet.
[32] In accordance with the embodiments of the present invention, the amount of linear low density polyethylene is up to 30 wt.% of the total weight of the carrier sheet.
[33] In accordance with the embodiments of the present invention, the amount of the roterproof material is in the range of 1 wt.% to 2 wt.% of the total weight of the carrier sheet.
[34] In accordance with the embodiments of the present invention, the waterproofing pressure sensitive adhesive membrane comprises materials like sand or gel and a hot melt pressure sensitive adhesive (HMPSA). The inorganic particulate material comprises at least one of sand, calcium carbonate, cement, and titanium dioxide dusted thereon.
[35] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of styrene-isoprene-styrene block copolymer in the range of 15 wt.% to 40 wt.% of total weight of the hot melt pressure sensitive adhesive.
[36] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of petroleum resin in range of 25 wt.% to 60 wt.% of total weight of the hot melt pressure sensitive adhesive.
[37] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of hydrotreated naphthenic distillate in range of 15 wt.% to 30% wt.% of total weight of the hot melt pressure sensitive adhesive.
[38] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes an amount of anti oxidants in the range of 25 wt.% to 45 wt.% of total weight of the hot melt pressure sensitive adhesive.
[39] In accordance with the embodiments of the present invention, the tape is polyethylene terephthalate (PET) tape with silicone adhesive.
[40] Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawing, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
[41] The detailed description is described with reference to the accompanying figures.
[42] Figure 1 depicts waterproofing membrane in accordance with the prior art;
[43] Figure 2 depicts a waterproofing membrane, in accordance with the embodiments of the present invention; and
[44] Figure 3 shows machine layout of an extruder with a tape applicator, in accordance with the embodiments of the present invention.
[45] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
[46] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of the invention as defined by the description. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[47] The terms and words used in the following description are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of the present invention is provided for illustration purpose only.
[48] It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.
[49] Referring to Figures 2-3, according to an aspect, the present invention discloses a process for manufacturing a waterproofing membrane having both uncoated sides and end. The process for manufacturing such a waterproofing membrane is explained herein below.
[50] In step 1 (S1) for manufacturing a waterproofing membrane, at least one polymeric material is extruded to form a thin carrier sheet.
[51] In accordance with the embodiments of the present invention, the step 1 (S1) of extruding the carrier sheet comprises the step of pre heating an extrusion die head (102), a feeding barrel (103) and an extrusion roll (104). In the next step, the polymeric material is dried in a drier (101) at a predefined temperature to obtain a dried polymeric material. In further step, the dried polymeric material is fed to the preheated feeding barrel (102). In the next step, the molten polymeric material is transported from the feeding barrel (102) to extrusion die head (106) via a melt pump (105). In a final step, the extrusion die head (106) is subjected for extruding a sheet to the calendaring rollers (104) to obtain a roll of the carrier sheet.
[52] In accordance with the embodiments of the present invention, the extrusion die head (102), the feeding barrel (103) and the extrusion roll (104) are preheated at a temperature in the range of 200 °C to 250 °C for a time period in the range of 2 hours to 5 hours.
[53] In accordance with the embodiments of the present invention, the polymeric material is selected from the group comprising of medium density polyethylene, linear low-density polyethylene.
[54] In accordance with the embodiments of the present invention, the polymeric material is dried at the predefined temperature in the range of 90 °C to 120 °C.
[55] In accordance with the embodiments of the present invention, the coating die head, the HMPSA tank and the sand tank are pre-heated at the temperature in the range of 145 °C to 160 °C
[56] In accordance with the embodiments of the present invention, the carrier sheet optionally includes a roterproof material mixed with the polymeric material. In an embodiment, the roterproof material includes a micro-porous polymer filled with a plurality of bitter compounds and at least one UV compound. In another embodiment, the UV compound is Denatonium benzoate. The micro-porous polymer protects the membrane from damaging effects of UV and heat exposure. Further, the roterproof material present in the membrane protects the structure from the attacks of termite, rodents and other parasites to the membrane.
[57] In accordance with the embodiments of the present invention, the medium density polyethylene is present in the range of 70 wt.% to 100 wt.% of the total weight of the carrier sheet.
[58] In accordance with the embodiments of the present invention, the linear low density polyethylene present is present up to 30 wt.% of the total weight of the carrier sheet.
[59] In accordance with the embodiments of the present invention, the roterproof material is present in the range of 1 wt.% to 2 wt.% of the total weight of the carrier sheet.
[60] In step 2 (S2) for manufacturing a waterproofing membrane, a tape is applied on at least one side of the carrier sheet at a predefined interval along a lateral direction.
[61] In accordance with the embodiments of the present invention, the step of applying tape in step (S2) is performed by a tape applicator (107) having a contact roll adapted to press tape against at least one side of the carrier sheet of step 1 (S1).
[62] In accordance with the embodiments of the present invention, the tape is polyethylene terephthalate (PET) tape with silicone adhesive. The polyethylene terephthalate (PET) tape with silicone adhesive, or any known tape that meet the properties such as Peel Adhesion (to panel) Min 14.5N/25mm width, endurance adhesion Min 24 hr, tensile strength min 135 N/25mm width, elongation Min 50%, breakdown voltage Min 6.0 KV, heat resistance between - 73? to 200? temperature, and solvent resistance. In an embodiment, the tape applicator is a lap lock tape applicator.
[63] In step 3 (S3) for manufacturing a waterproofing membrane, a waterproofing pressure sensitive adhesive membrane is coated on at least one side of the carrier sheet along the longitudinal direction. The waterproofing pressure sensitive adhesive membrane is coated on at least one side of the carrier sheet having a width less than the actual width of the carrier sheet thereby leaving other sides uncoated.
[64] In accordance with the embodiments of the present invention, the step 3 (S3) of coating the waterproofing pressure sensitive adhesive membrane on at least one side of the carrier sheet comprises the step of obtaining the waterproofing pressure sensitive adhesive membrane materials. The adhesive membrane material comprises sand or gel and a hot melt pressure sensitive adhesive (HMPSA). In the next step, the HMPSA is stored in a HMPSA tank and sand is stored in a sand tank. Further, a coating die head, the HMPSA tank and the sand tank are pre-heated. In the next step, a gap between the coating die head and rollers is adjusted based on the sheet thickness to obtain the coating of a predetermined thickness. In further step, the roll of the carrier sheet obtained in step 2 (S2) is loaded onto the unwinding section of the coating machine. The roll is locked, and the starting portion of the roll is joined to the end portion of the previous roll sheet. The sheet edges are maintained within the marked guide lines using a plurality of sensors. In the next step, the rewinding section panel is operated to set desired roll length. In the further step, the die head is pressed onto the surface of the carrier sheet once the sheet starts moving to coat the carrier sheet such that sides of the carrier sheet are uncoated in the longitudinal direction and end of the carrier sheet is uncoated in the lateral direction to obtain the waterproofing membrane.
[65] In accordance with the embodiments of the present invention, the maximum coating width is 200 mm less than the actual membrane width for heat sealing side laps. In another embodiment, each roll of waterproofing membrane coated with sand/gel and HMPSA layer has at least 100 mm at either side without the sand/gel and HMA layer for heat sealing side laps. The overlapping sides are heat sealed. Uncoated surfaces are present on both sides as well as at the ends of each roll of membrane allowing extreme ease of application in site with respect to membrane overlaps, joints and terminations.
[66] In accordance with the embodiments of the present invention, the process for manufacturing a waterproofing membrane optionally comprises the step of coating a protective layer on the waterproofing pressure sensitive adhesive membrane. In an embodiment, the protective layer comprises a coating or dusting of finely divided inorganic particulate material on an outer exposed surface thereof.
[67] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive (HMPSA) comprises a predetermined amount of styrene-isoprene-styrene block copolymer in the range of 15 wt.% to 40 wt.% of total weight of the hot melt pressure sensitive adhesive, a predetermined amount of petroleum resin in range of 25 wt.% to 60 wt.% of total weight of the hot melt pressure sensitive adhesive, a predetermined amount of hydrotreated naphthenic distillate in range of 15 wt.% to 30% wt.% of total weight of the hot melt pressure sensitive adhesive and a predetermined amount of anti oxidants in the range of 25 wt.% to 45 wt.% of total weight of the hot melt pressure sensitive adhesive.
[68] In accordance with the embodiments of the present invention, the inorganic particulate material comprises at least one of sand, calcium carbonate, cement, and titanium dioxide dusted thereon.
[69] In accordance with the embodiments of the present invention, the process for manufacturing a waterproofing membrane optionally comprises applying a substrate along and adjacent one edge of the carrier sheet. In an embodiment, the substrate is a film or paper coated with a release agent on both surface and being removably adhered to either the pressure sensitive adhesive membrane or the protective layer.
[70] In accordance with the embodiments of the present invention, the film is selected from at least one of polyethylene, polypropylene, polyethylene terephthalate, and polyamide. In another embodiment, the release agent is silicone.
[71] In step 4 (S4) for manufacturing a waterproofing membrane, the tape is removed to provide uncoated end at predefined interval to produce the waterproofing membrane having uncoated sides and uncoated ends.
[72] In accordance with the embodiments of the present invention, the tape has 210 mm width applied on the carrier sheet in the lateral direction at the predefined interval of every 20 m. Once the roll reaches a set roll length, for example, 20 meters at the rewinding section, the machine cuts and packages the roll. The cutting is made ensured that at the center of the pasted tape which is 210 mm in width so that one complete roll has 100+ mm tape at both ends. After each jumbo roll is finished at the unwinding section, the rolls collected at the trolley are moved to storage area to load and dispatch.
[73] As the so obtained waterproof membrane in accordance with the process of the present invention has both uncoated sides and ends, the waterproof membrane allows to be heat sealed readily and easily without the hassle of removing coating layer.
[74] In another aspect, the present invention discloses a waterproofing membrane comprising a thin carrier sheet having a removable tape adhered at a predefined interval along a lateral direction on at least one side of the carrier sheet and a waterproofing pressure sensitive adhesive membrane coated on at least one side of the carrier sheet, along the longitudinal direction, leaving uncoated sides therein.
[75] In accordance with the embodiments of the present invention, the uncoated sides are formed as the width of the waterproofing pressure sensitive adhesive membrane coating on at least one side of the carrier sheet is less than the actual width of the carrier sheet.
[76] In accordance with the embodiments of the present invention, the waterproofing membrane optionally comprises a protective layer coated on the waterproofing pressure sensitive adhesive membrane, the protective layer comprises a coating or dusting of finely divided inorganic particulate material on an outer exposed surface thereof.
[77] In accordance with the embodiments of the present invention, the waterproofing membrane optionally comprises a substrate along and adjacent one edge of the carrier sheet, the substrate having a film or paper coated with a release agent on both surface and being removably adhered to either the pressure sensitive adhesive membrane or the protective layer.
[78] In accordance with the embodiments of the present invention, the polymeric material is selected from the group comprising of medium density polyethylene, linear low-density polyethylene.
[79] In accordance with the embodiments of the present invention, the carrier sheet optionally includes a roterproof material mixed with the polymeric material, the roterproof material includes a micro-porous polymer filled with a plurality of bitter compounds and at least one UV compound. In another embodiment, the UV compound is Denatonium benzoate.
[80] In accordance with the embodiments of the present invention, the medium density polyethylene is present in the range of 70 wt.% to 100 wt.% of the total weight of the carrier sheet.
[81] In accordance with the embodiments of the present invention, the linear low density polyethylene is present up to 30 wt.% of the total weight of the carrier sheet.
[82] In accordance with the embodiments of the present invention, the amount of the roterproof material is present in the range of 1 wt.% to 2 wt.% of the total weight of the carrier sheet.
[83] In accordance with the embodiments of the present invention, the waterproofing pressure sensitive adhesive membrane comprises materials like sand or gel and a hot melt pressure sensitive adhesive (HMPSA). The inorganic particulate material comprises at least one of sand, calcium carbonate, cement, and titanium dioxide dusted thereon.
[84] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of styrene-isoprene-styrene block copolymer in the range of 15 wt.% to 40 wt.% of total weight of the hot melt pressure sensitive adhesive.
[85] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of petroleum resin in range of 25 wt.% to 60 wt.% of total weight of the hot melt pressure sensitive adhesive.
[86] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of hydrotreated naphthenic distillate in range of 15 wt.% to 30% wt.% of total weight of the hot melt pressure sensitive adhesive.
[87] In accordance with the embodiments of the present invention, the hot melt pressure sensitive adhesive includes a predetermined amount of anti oxidants in the range of 25 wt.% to 45 wt.% of total weight of the hot melt pressure sensitive adhesive.
[88] In accordance with the embodiments of the present invention, the tape is polyethylene terephthalate (PET) tape with silicone adhesive.
[89] The waterproofing membrane obtained in accordance with the process of the present invention is advantageous in that it has uncoated sides as well as ends which is useful for forming strong side as well as ends. Further, for joining two or more membranes to each other, removal of coating layer from sides and ends of the membranes is not required as the sides and ends of the membranes are uncoated. Therefore, the process of the present invention overcomes the additional time and labour required for removal of the coating layer having sand/gel and HMA to create end joints. Hence, the process of the present invention is simple, economical and eliminates the complex construction processes that require additional tools for removal of coating layer for overlapping the membranes.
[90] Further, the method of the present invention provides at least 100 mm overlap area at the sides as well as the ends without the coating layer of HMA and sand/gel of each HDPE waterproofing sanded/gelled membrane roll which allow the overlapping, joining and termination through heat sealing or through affixing tapes without having to remove any coating layer of sand/gel and HMA. Therefore, joined waterproofing membranes of the present invention have strong end as well as side joints.
[91] Furthermore, the method of the present invention provides waterproofing membrane which offers end laps in addition to side laps without the sand/gel and HMA layer from the manufacturer makes heat sealing easier and more convenient and offers a gateway to more improved joints by making sealing easier and offering an extra zone to seal (end laps) as well.
[92] The waterproofing membrane of the present invention ensures waterproof joints, overlaps especially in applications with higher water table where the waterproofing membrane system comes under higher pressure and load from water as it holds the joints, overlaps and terminations with immense strength due to side as well as ends are lap lock joints produced by heat sealing.
[93] The terms and words used in the following description are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of the system is for the purpose of understanding and nowhere limit the invention. The abovementioned parts nowhere limit the invention and are provided for understanding of the invention.
[94] Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims.
,CLAIMS:
1. A process for manufacturing a waterproofing membrane comprising the steps
of:
step 1 (S1) of extruding at least one polymeric material to form a thin carrier sheet;
step 2 (S2) of applying a tape on at least one side of the carrier sheet at a predefined interval along lateral direction;
step 3 (S3) of coating a waterproofing pressure sensitive adhesive membrane on the at least one side of the carrier sheet along the longitudinal direction, wherein the waterproofing pressure sensitive adhesive membrane is coated on the at least one side of the carrier sheet having a width less than the actual width of the carrier sheet thereby leaving other sides uncoated; and
step 4 (S4) of removing the tape to provide uncoated end at predefined interval to produce the waterproofing membrane having uncoated sides and uncoated ends.
2. The process as claimed in claim 1, wherein the step 1 (S1) of extruding the carrier sheet (S1) comprising the steps of:
i. pre heating an extrusion die head, a feeding barrel and an extrusion roll;
ii. drying the polymeric material at a predefined temperature to obtain a dried polymeric material;
iii. feeding the dried polymeric material to the preheated feeding barrel;
iv. transporting the molten polymeric material from the feeding barrel to extrusion die head via a melt pump; and
v. subjecting the extrusion die head for extruding a sheet to the calendaring rollers to obtain a roll of the carrier sheet.
3. The process as claimed in claim 1 or 2, wherein the step 2 (S2) of applying tape is performed by a tape applicator having a contact roll that presses tape against the side of the carrier sheet of step 1 (S1).
4. The process as claimed in any one of claims 1 to 3, wherein the step 3 (S3) of coating the waterproofing pressure sensitive adhesive membrane on the at least one side of the carrier sheet comprising the steps of:
i. obtaining the waterproofing pressure sensitive adhesive membrane materials comprising sand or gel and a hot melt pressure sensitive adhesive (HMPSA);
ii. storing the HMPSA and sand in a HMPSA tank and a sand tank respectively;
iii. pre-heating a coating die head, the HMPSA tank and the sand tank;
iv. adjusting a gap between the coating die head and rollers based on the sheet thickness to obtain the coating of a predetermined thickness;
v. loading the roll of the carrier sheet obtained in step 2 (S2) onto the unwinding section of the coating machine;
vi. locking the roll and joining the starting portion of the roll to the end portion of the previous roll sheet;
vii. maintaining the sheet edges within the marked guide lines using a plurality of sensors;
viii. setting desired roll length in the rewinding section panel; and
ix. pressing the die head onto the surface of the carrier sheet once the sheet starts moving to coat the carrier sheet such that sides of the carrier sheet are uncoated in the longitudinal direction and end of the carrier sheet is uncoated in the lateral direction to obtain the waterproofing membrane.
5. The process as claimed in claim 1, wherein the waterproofing pressure sensitive adhesive membrane optionally coated with a protective layer that comprises a coating or dusting of finely divided inorganic particulate material on an outer exposed surface thereof.
6. The process as claimed in claim 1 or 5, wherein the carrier sheet optionally applied with a substrate along and adjacent one edge of the carrier sheet such that the substrate is having a film or paper coated with a release agent on both surface and being removably adhered to either the pressure sensitive adhesive membrane or the protective layer.
7. The process as claimed in claim 2, wherein the extrusion die head, the feeding barrel and the extrusion roll are preheated at a temperature in the range of 200 °C to 250 °C for a time period in the range of 2 hours to 5 hours.
8. The process as claimed in claim 1 or 2, wherein the polymeric material is selected from the group of medium density polyethylene, and linear low-density polyethylene.
9. The process as claimed in claim 1, wherein the carrier sheet optionally includes a roterproof material mixed with the polymeric material.
10. The process as claimed in claim 2, wherein the polymeric material is dried at the temperature in the range of 90 °C to 120 °C.
11. The process as claimed in claim 4, wherein the coating die head, the HMPSA tank and the sand tank are pre-heated at the temperature in the range of 145 °C to 160 °C.
12. The process as claimed in claim 1 or 3, wherein the tape is polyethylene terephthalate (PET) tape with silicone adhesive.
13. The process as claimed in claim 3, wherein the tape applicator is a lap lock tape applicator.
14. The process as claimed in claim 1, wherein the maximum coating has a width that is 200 mm less than the actual membrane width to ensure at least 100 mm width is retained at either side for heat sealing of the side laps.
15. The process as claimed in claim 1, wherein the tape has a width of 210 mm applied on the carrier sheet in the lateral direction at the predefined interval of 20 m.
16. The process as claimed in claim 6, wherein said film is selected from at least one of polyethylene, polypropylene, polyethylene terephthalate, and polyamide.
17. The process as claimed in claim 6, wherein said release agent is silicone.
18. A waterproofing membrane comprising:
a thin carrier sheet having a removable tape adhered thereon, the removable tape is adhered on at least one side of the carrier sheet at a predefined interval along a lateral direction, and the at least one side of the carrier sheet having a waterproofing pressure sensitive adhesive membrane coated thereon, along the longitudinal direction thereby leaving uncoated sides therein.
19. The waterproofing membrane as claimed in claim 18, wherein the waterproofing pressure sensitive adhesive membrane coating on the at least one side of the carrier sheet has a width that is less than the actual width of the carrier sheet.
20. The waterproofing membrane as claimed in claim 18, wherein the waterproofing pressure sensitive adhesive membrane optionally comprises a protective layer, that comprises a coating or dusting of finely divided inorganic particulate material on an outer exposed surface thereof.
21. The waterproofing membrane as claimed in claim 18 or 20, wherein the carrier sheet optionally comprises a substrate along and adjacent one edge thereof.
22. The waterproofing membrane as claimed in claim 21, wherein the substrate is having a film or paper coated with a release agent on both surface and being removably adhered to either the pressure sensitive adhesive membrane or the protective layer.
23. The waterproofing membrane as claimed in claim 18, wherein the polymeric material is selected from the group comprising of medium density polyethylene, and linear low-density polyethylene.
24. The waterproofing membrane as claimed in claim 18, wherein the carrier sheet optionally includes a roterproof material mixed with the polymeric material, the roterproof material includes a micro-porous polymer filled with a plurality of bitter compounds and at least one UV compound.
25. The waterproofing membrane as claimed in claim 24, wherein the UV compound is Denatonium benzoate.
26. The waterproofing membrane as claimed in claim 24, wherein the amount of medium density polyethylene is in the range of 70 wt.% to 100 wt.% of the total weight of said carrier sheet.
27. The waterproofing membrane as claimed in claim 24, wherein the amount of linear low density polyethylene is up to 30% wt.% of the total weight of said carrier sheet.
28. The waterproofing membrane as claimed in claim 24, wherein the amount of the roterproof material is in the range of 1 wt.% to 2 wt.% of the total weight of said carrier sheet.
29. The waterproofing membrane as claimed in claim 18, wherein the waterproofing pressure sensitive adhesive membrane comprises materials like sand or gel and a hot melt pressure sensitive adhesive (HMPSA).
30. The waterproofing membrane as claimed in claim 29, wherein the hot melt pressure sensitive adhesive includes a predetermined amount of styrene-isoprene-styrene block copolymer in the range of 15 wt.% to 40 wt.% of total weight of said hot melt pressure sensitive adhesive.
31. The waterproofing membrane as claimed in claim 29, wherein the hot melt pressure sensitive adhesive includes a predetermined amount of petroleum resin in range of 25 wt.% to 60 wt.% of total weight of said hot melt pressure sensitive adhesive.
32. The waterproofing membrane as claimed in claim 29, wherein the hot melt pressure sensitive adhesive includes a predetermined amount of hydrotreated naphthenic distillate in range of 15 wt.% to 30% wt.% of total weight of said hot melt pressure sensitive adhesive.
33. The waterproofing membrane as claimed in claim 29, wherein the hot melt pressure sensitive adhesive includes a predetermined amount of anti oxidants in the range of 25 wt.% to 45 wt.% of total weight of said hot melt pressure sensitive adhesive.
34. The waterproofing membrane as claimed in claim 18, wherein the tape is polyethylene terephthalate (PET) tape with silicone adhesive.
35. The waterproofing membrane as claimed in claim 20, wherein the inorganic particulate material comprises at least one of sand, calcium carbonate, cement, and titanium dioxide dusted thereon.
36. The waterproofing membrane as claimed in claim 22, wherein the film is selected from at least one of polyethylene, polypropylene, polyethylene terephthalate, and polyamide.
37. The waterproofing membrane as claimed in claim 22, wherein said release agent is silicone.