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JP-2026514328-A - Method for manufacturing a pressure-sensitive adhesive with sufficient moisture permeability and related system

JP2026514328AJP 2026514328 AJP2026514328 AJP 2026514328AJP-2026514328-A

Abstract

A method for foaming an adhesive includes the step of injecting gas into a liquid adhesive to reduce its density. The method also includes the step of mixing the gas-impregnated adhesive to produce a foamed adhesive having numerous small bubbles throughout the adhesive, where at least 80% of the bubbles are 0.005 microns or larger in size. The method then includes the step of curing the foamed adhesive to maintain the size of each bubble formed in the foamed adhesive.

Inventors

  • スナイダー リーランド
  • ノーラン ケビン ディー．
  • ブラックオウィッツ スティーブン

Assignees

  • バプロシールド エルエルシー

Dates

Publication Date
20260511
Application Date
20240408
Priority Date
20230410

Claims (16)

  1. A method for foaming adhesive, A step of injecting gas into a liquid adhesive to reduce the density of the adhesive, A step of mixing the gas-impregnated adhesive to produce a foamed adhesive having numerous small bubbles throughout the adhesive, wherein at least 80% of the bubbles are 0.005 microns or larger in size. A step of curing the foamed adhesive to maintain the size of each bubble formed in the foamed adhesive, Methods that include...
  2. The adhesive is an acrylic pressure-sensitive adhesive. The method according to claim 1.
  3. The specific gravity of the adhesive is 1.1. The method according to claim 1.
  4. Injecting the gas into the adhesive includes injecting air. The method according to claim 1.
  5. Injecting the gas into the adhesive is The process involves injecting the gas through a nozzle located inside the chamber while the adhesive is flowing through the chamber. The method according to claim 1.
  6. The gas is injected at a rate of 0.2 to 0.02 cubic feet per minute. The method according to claim 5.
  7. The adhesive flows through the chamber at a rate of 0.5 to 2.0 gallons per minute. The method according to claim 5.
  8. The gas is injected into the adhesive at a rate of 0.08 cubic feet per minute. The adhesive flows through the chamber at a rate of 1.14 gallons per minute. The method according to claim 5.
  9. Mixing the adhesive impregnated with the aforementioned gas is This includes shearing the adhesive between the stator and rotor of the mixer. The method according to claim 1.
  10. Mixing the adhesive impregnated with the aforementioned gas is Pumping the gas-impregnated adhesive through a mixer having a stator and a rotor so that the gas-impregnated adhesive flows between the teeth of the stator and the teeth of the rotor, With the gas-impregnated adhesive flowing between the teeth of the stator and the teeth of the rotor, the rotor of the mixer is moved relative to the stator such that the teeth of the rotor pass near the teeth of the stator and shear the gas-impregnated adhesive. including, The method according to claim 1.
  11. The relative density of the foamed adhesive before curing is 0.45 to 0.95 times that of the liquid adhesive before gas injection. The method according to claim 1.
  12. The relative density of the foamed adhesive before curing is 0.7 relative to the density of the liquid adhesive before gas injection. The method according to claim 1.
  13. Curing the foamed adhesive includes heating the foamed adhesive. The method according to claim 1.
  14. The process further includes holding the foam adhesive before curing it. The method according to claim 1.
  15. The process further includes applying the foam adhesive to the substrate before curing the adhesive. The method according to claim 1.
  16. By mixing the gas-impregnated adhesive, a foamed adhesive is produced, which generates a large number of small bubbles throughout the adhesive. At least 80% of the bubbles are in the size range of 0.005 to 50 microns. The method according to claim 1.

Description

Interrelationships of references and incorporation of citations This application claims priority to U.S. Provisional Patent Application No. 63/495,252, “Method for Manufacturing a Pressure-Sensitive Adhesive with Sufficient Moisture Permeability and Related System,” filed on April 10, 2023. Furthermore, this application incorporates the entire contents of U.S. Provisional Patent Application No. 63/495,252 by reference herein. Architects and engineers agree that buildings must be able to dry. However, commonly used underlayment and membranes trap condensation and moisture within walls, leading to reduced indoor air quality, decreased energy efficiency, and costly damage to buildings. The North American construction industry spends approximately $9 billion annually on repairs and lawsuits related to water and moisture damage. While new materials used in construction over the past 20 years are energy-efficient, they offer poor ventilation, resulting in over $3 billion in claims related to toxic mold. Air leaks from such membranes can increase energy consumption by up to 30-40% in heated climates and 10-15% in cooled climates. Proper building envelope design promotes continuous drying by allowing water vapor to escape. Moisture can penetrate the building envelope through materials or through exposure to rain and snow during construction. Furthermore, general occupancy also increases moisture levels. Trapped moisture can cause wood rot, swelling, and warping, metal corrosion, and reduced insulation performance. All of these issues increase the risk of mold growth, building deterioration, reduced indoor air quality, and health and safety risks to occupants. In some states, new requirements for improved energy efficiency in buildings increase the likelihood of moisture trapping when using low-permeability or non-permeable air barriers. Figure 1 shows a schematic diagram of a system for foaming an adhesive according to one embodiment of the present invention.Figure 2A shows a side view of a system for foaming an adhesive according to one embodiment of the present invention.Figure 2B shows a front view of a system for foaming an adhesive according to one embodiment of the present invention.Figure 3 shows an exploded schematic diagram of the mixer of the system shown in Figures 2A and 2B for mixing adhesives according to one embodiment of the present invention.Figure 4A shows a perspective view of the stator of the mixer shown in Figure 3 for mixing adhesives according to one embodiment of the present invention.Figure 4B shows a perspective view of the rotor of the mixer shown in Figure 3 for mixing adhesives according to one embodiment of the present invention.Figure 5 shows a cross-sectional view of a portion of the rotor and stator connected in the mixer shown in Figure 3 for mixing adhesive according to one embodiment of the present invention. Figure 1 shows a schematic diagram of a manufacturing process 20 for foaming an adhesive according to one embodiment of the present invention. The manufacturing process 20 includes, in step 22, injecting gas into the liquid adhesive to generate bubbles within the adhesive and reduce the density of the adhesive, and in the subsequent step 24, mixing the gas-impregnated adhesive to complete the formation of bubbles within the adhesive. At this stage, the microstructure of the adhesive contains a large number of small bubbles. After the microstructure of the adhesive is formed, the manufacturing process 20 includes, in step 26, curing the adhesive to maintain the size and distribution of each bubble within the microstructure of the adhesive. The foamed adhesive obtained as a result of the manufacturing process 20 has a density range of 15% to 90% of the density of the liquid adhesive before foaming, and its microstructure contains a large number of minute pores (bubbles). In this embodiment, the manufacturing process 20 is carried out as a continuous manufacturing process. In a continuous manufacturing process, gas is injected into the adhesive, and the liquid adhesive flows continuously to the curing process with the gas-impregnated adhesive mixed. In another embodiment, manufacturing step 20 may be carried out as a single manufacturing step. In a single manufacturing step, a predetermined amount of liquid adhesive is held in a container with gas injected into it. After all the gas has been injected into the adhesive, the entire amount of adhesive is mixed. By injecting gas into the adhesive while it is in a liquid state, and then mixing the gas-impregnated adhesive, numerous small bubbles can be formed in the adhesive's microstructure without requiring heating. This makes the size of the numerous small bubbles more uniform and improves the controllability of bubble size. The numerous small, uniformly sized bubbles in the foamed adhesive make it more permeable to water vapor, improving its Perm value (water permeability). The numerous small, uniformly sized bubbles in the foa