Integrated air barrier assembly

Patent metadata

Field	Value
Publication number	US-12134246-B2
Application number	US-201816770171-A
Country	US
Kind code	B2
Filing date	Dec 6, 2018
Priority date	Dec 7, 2017
Publication date	Nov 5, 2024
Grant date	Nov 5, 2024

Abstract

An integrated air barrier assembly is provided as an integral product in which a fastener-sealing layer is secured between opposed surfaces of a board and an anti-blocking facing layer. The assembly exhibits good fastener sealability, including for larger self-drilling screws. The anti-blocking facing layer maintains the fastener-sealing layer inward of the environment and prevents blocking or sticking of the assembly when stacked. In some embodiments, the anti-blocking facing layer can be a metal film or foil, which can reflect heat away from the fastener-sealing layer, thereby maintaining a lower temperature on the fastener-sealing layer. In some embodiments, the board can be an insulating layer or wood layer. The assembly can be readily installed in a single step during construction.

First claim

What is claimed is:

1. An integrated air barrier assembly comprising:
a board including a first surface and a second surface;
a fastener-sealing layer comprising a liquid-applied coating composition adhered on one of the first surface or the second surface of the board, wherein the fastener-sealing layer has a glass transition temperature of equal to or less than 40° F. such that the fastener-sealing layer is soft enough to seal around a shaft of a fastener and has a thickness ranging from 1 mils to 50 mils, wherein the liquid-applied coating composition comprises at least one of a liquid-applied latex, acrylic, vinyl acrylic, styrene acrylate, vinyl acetate, styrene-butadiene, carboxylated styrene-butadiene, vinylidene chloride, asphaltic emulsion, natural rubber, butyl, chloroprene, vinyl chloride-ethylene, and polyvinyl chloride; and
an anti-blocking facing layer adhered on a surface of the fastener-sealing layer opposite the board such that the fastener-sealing layer is disposed between the board and the anti-blocking facing layer, wherein the anti-blocking facing layer is chosen from a fiberglass mat, an aluminum foil, a fabric layer, or a paper layer, or a combination thereof,
wherein the assembly has an air leakage of less than 0.02 L/sec-m 2 as measured by ASTM Test Method E 2178 (2003) at a pressure difference of 75 Pa.

2. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer is aluminum foil thus making the assembly water vapor impermeable characterized by having a water vapor permeance less than 1 perm at a temperature of 23° C. and a relative humidity of 100% on one side and 50% on an opposite side, as measured by ASTM Test Method E 96 B (2010).

3. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer is the fiberglass mat, the fabric layer, or the paper layer thus making the assembly vapor permeable characterized by having a water vapor permeance of greater than 10 perms at a temperature of 23° C. and a relative humidity of 100% on one side and 50% on an opposite side, as measured by ASTM Test Method E 96 B (2010).

4. The integrated air barrier assembly of claim 1 , wherein the assembly has an air leakage rate of greater than 75 Pa as measured by ASTM Test Method E 1186 (2003).

5. The integrated air barrier assembly of claim 1 , wherein the fastener-sealing layer seals a penetration formed by a self-driving screw.

6. The integrated air barrier assembly of claim 1 , wherein the fastener-sealing layer includes a plasticizer chosen from a phthalate, benzoate ester, polyether, polyester, adipate, polyetheramine, polyol, or epoxidized soybean oil, or a combination thereof.

7. The integrated air barrier assembly of claim 1 , wherein the fastener-sealing layer is a composition applied as a hot melt, wherein the hot melt composition is chosen from a polyolefin, ethylene vinyl acetate, polyamide, polyurethane, asphaltic, butyl, or acrylic, or a combination thereof.

8. The integrated air barrier assembly of claim 1 , wherein the fastener-sealing layer is a composition applied as a low molecular weight liquid that crosslinks to form a solid coating, the composition comprising a polyurethane, polyurea, acrylic, silicone, silyl terminated polyether, epoxy, or a combination thereof.

9. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer is solid below at least 160° F.

10. The integrated air barrier assembly of claim 9 , wherein the anti-blocking facing layer is the fiberglass mat comprising E glass fibers or S glass fibers embedded in a resin matrix chosen from a thermoset resin, thermoplastic resin, latex resin, polyester resin, amino resin, formaldehyde resin, epoxy resin, or a combination thereof.

11. The integrated air barrier of claim 1 , wherein the anti-blocking facing layer is the aluminum foil having a thickness of 0.025 mm to 0.5 mm.

12. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer comprises a radiant barrier disposed to redirect thermal radiation away from the fastener-sealing layer.

13. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer is the paper layer comprising a coated paper.

14. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer is the fabric layer chosen from a woven material, a non-woven material, a felt material or a spun bond material.

15. The integrated air barrier assembly of claim 1 , wherein the anti-blocking facing layer is the fabric layer chosen from a polyethylene, polypropylene, or polyester non-woven fabric.

16. The integrated air barrier assembly of claim 1 , wherein the board comprises an insulating layer having an R-value of at least 1.

17. The integrated air barrier assembly of claim 16 , wherein the insulating layer comprises an insulating material chosen from a polyisocyanurate, expanded polystyrene, or extruded polystyrene, or a combination thereof.

18. The integrated air barrier assembly of claim 1 , wherein the board comprises a wood layer chosen from oriented strand board, plywood, particle board, chip board, medium density fiberboard, wafer board, wood particles in laminate or non-laminate form, composites of strands and ply veneers, or composites of wood chips.

19. The integrated air barrier assembly of claim 1 , wherein the board is chosen from a gypsum board, a concrete masonry unit, or a cementitious board.

20. The integrated air barrier assembly of claim 1 wherein the fastener-sealing layer has a glass transition temperature of equal to or less than 25° F.

21. The integrated air barrier assembly of claim 1 wherein the fastener-sealing layer has a glass transition temperature of equal to or less than 20° F.

22. A sheathing system for a building structure, comprising:
a wall or roof panel having an interior surface and an exterior surface; and
the integrated air barrier assembly of claim 1 secured to one of the exterior surface or the interior surface of the wall or roof panel.

23. A method of sheathing an exterior wall or roof of a building structure, comprising:
fastening at least two integrated air barrier assemblies of claim 1 to structural support elements of the building structure, with a transverse edge of one integrated air barrier assembly located proximate to a transverse edge of an adjacent integrated air barrier assembly to define a joint therebetween.

Assignees

• Gcp Applied Tech Inc

Inventors

• Couturier Marysusan
• Seth Jyoti
• Boyer Damla

Classifications

• E04C2/26

  composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups {(of cement and mineral fibres E04C2/04)} · CPC title

• E04B2103/04

  of plastics, fibrous material or wood · CPC title

• E04B2103/02

  of ceramics, concrete or other stone-like material · CPC title

• E04B1/665 Primary

  Sheets or foils impervious to water and water vapor · CPC title

• C09D195/005

  Aqueous compositions, e.g. emulsions · CPC title