US-12623436-B2 - Barrier composite with an integral release layer and method of making same

Abstract

A barrier composite has a barrier layer that is water resistant, and adhesive for applying the barrier composite to an external wall surface and an integral release layer to allow the adhesive to release such that a roll or barrier composite can be unspooled and attached directly the said wall surface without removing a release liner. A barrier composite may also include a plurality of stand-offs extending to an exterior surface of the barrier composite and configured to allow precipitation that has passed through the outer shingles to flow down along the barrier composite. The integral release layer may be configured on, in or over the stand-offs. The stand-offs may be configured with a material that prevents the adhesive from adhering or that splits or fractures to produce stand-off deposits. Alternatively, the adhesive may be configured to wick into the stand-offs and then split producing adhesive deposits on the stand-offs.

Inventors

• Manish Seth
• Gregory K. Jones

Assignees

• ARISTA CONSTRUCTION SYSTEMS FZE

Dates

Publication Date

20260512

Application Date

20221215

Claims (20)

1. 1 . A method of adhering a drainage barrier composite to a wall surface comprising: a) providing a barrier layer composite roll comprising: a barrier layer that is water resistant, wherein liquid water will not pass through the barrier composite for 5 minutes with a 25 mm water column; an adhesive, wherein the adhesive is attached to an interior surface of the barrier layer; an integral release material; wherein the integral release material is configured on the barrier layer opposite said interior surface of the barrier layer to form bonded areas of the integral release material that are bonded to the barrier layer and non-bonded areas of the integral release material that are not bonded to the barrier layer; wherein the barrier composite roll has a plurality or layers with an adhesive layer of a first layer of barrier composite adjacent the integral release material of a second layer of the barrier composite; and wherein the non-bonded areas of the integral release material of said second layer of the barrier composite are configured to fracture and stick to said adhesive layer of said first layer of barrier composite when the barrier composite roll is unspooled b) unrolling the draining barrier composite and during unrolling separating a portion of the integral release layer onto the adhesive layer; and c) pressing the adhesive layer of the barrier composite onto said exterior wall surface to adhere the barrier composite to said exterior surface.
2. 2 . The method of claim 1 , wherein the integral release material is an integral release film.
3. 3 . The method of claim 2 , wherein the integral release film is a polymeric film.
4. 4 . The method of claim 3 , wherein the integral release material is a continuous polymeric over the barrier layer.
5. 5 . The method of claim 1 , wherein the non-bonded areas form no more than 75% of a surface area of the integral release film.
6. 6 . The method of claim 1 , wherein the non-bonded areas form no more than 50% of a surface area of the integral release film.
7. 7 . The method of claim 1 , wherein the non-bonded areas form no more than 75% of a surface area of the integral release film and are discrete areas.
8. 8 . The method of claim 7 , wherein the integral release film is a polymeric film.
9. 9 . The method of claim 1 , wherein the adhesive is a pressure sensitive adhesive.
10. 10 . The method of claim 1 , wherein the barrier layer further comprises stand-offs configured on an opposite side of the barrier layer from the adhesive layer; wherein said stand-offs have a height of at least 0.2 mm; and wherein the integral release material extends over the stand-offs; and wherein the stand-offs provide water drainage when attached to said exterior wall surface.
11. 11 . The method of claim 10 , wherein the bonded portions of the integral release film are configured between the stand-offs and wherein the integral release layer is not attached to an extended end of the stand-offs.
12. 12 . The method of claim 10 , wherein the bonded portions of the integral release film are bonded by melt lamination.
13. 13 . The method of claim 12 , wherein the stand-off layer is a continuous stand-off layer extending over the barrier layer.
14. 14 . The method of claim 13 , wherein the continuous stand-off layer comprises compressed portions that form the stand-offs.
15. 15 . The method of claim 14 , wherein the integral release film is melt bonded to the compressed portions of the continuous stand-off layer.
16. 16 . The method of claim 14 , wherein the integral release film is attached to the compressed portions of the continuous stand-off layer by an adhesive.
17. 17 . The method of claim 10 , wherein the stand-off precursor is a multilayer fabric having an exterior layer and a barrier-side layer attached to the barrier layer.
18. 18 . The method of claim 10 , wherein the stand-offs have an area density at least 25%.
19. 19 . The method of claim 10 , wherein the stand-offs are discrete stand-offs.
20. 20 . The method of claim 10 , wherein the stand-offs are elongated stand-offs having a length that is at least twice a width.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. provisional application No. 63/290,015, filed on Dec. 15, 2021; the entirety of which is hereby incorporated by reference herein. BACKGROUND OF THE INVENTION Field of the Invention The invention relates to barrier composites with an integral release layer to allow an adhesive layer in a roll of barrier composite to release from an adjacent layer such that the roll can be unspooled and then be adhered to an exterior of a building to provide a barrier from precipitation and in some cases the integral release layer is configured on stand-offs that are configured to allow drainage of precipitation to drain down along the barrier layer and away from the building. Background Housewrap is used to prevent precipitation from contacting the exterior wall board or surface of a building or home. The housewrap has a barrier layer that is water resistance to prevent water from passing therethrough. Housewrap also insulates the building by preventing bulk flow of air through the seams in the exterior wall board. A housewrap material is placed between the exterior wall board, such as plywood, and the outer shingles or siding of the home. Housewrap may include an adhesive that enables a sheet of the housewrap to be adhered directly to the exterior wall board. The adhesive is covered with a detachable release film and removing this release film is difficult and causes handling issues and waste. Also, when peeling off the detachable release film, the housewrap can stick to itself thereby causing the sheet to be scrapped. In addition, precipitation that passes through the shingles may get trapped between the shingles and the housewrap when there is no gap to allow this penetrated water to drain. Therefore, efforts have been made to produce housewrap with spacers or stand-offs incorporated therein. These stand-offs however are typically low density, and can become compressed when the shingles are applied over the housewrap, thereby preventing proper drainage of water. Also, some stand-offs are discrete stand-offs that are applied or adhered discretely to the housewrap which can lead to detachment, or the discrete stand-offs being dislodged. SUMMARY OF THE INVENTION The invention is directed to barrier composites with an integral release layer to allow an adhesive layer in a roll of barrier composite to release from an adjacent layer such that the roll can be unspooled and then be adhered to an exterior of a building to provide a barrier from precipitation. An integral release layer or material is configured to allow the adhesive of an adjacent layer to easily release and maintain adhesion properties for adhesion to a wall board. An integral release layer may be a film or fabric that is configured to fracture or split and stick to the adhesive when the roll of barrier composite is unspooled. In some cases, the integral release layer is configured on stand-offs that are configured to allow drainage of precipitation to drain down along the barrier layer and away from the building. The barrier composite is configured with an adhesive on an interior surface of the barrier composite, or on an opposite side of the barrier layer from the integral release layer and/or the stand-offs, which are configured on an exterior surface. The integral release layer is configured to eliminate the need for a separate detachable release layer that is configured between the adhesive and adjacent layers in a roll of barrier layer composite. An integral release layer may be configured with a material that prevents the adhesive from adhering or that splits or fractures to produce deposits. Alternatively, the adhesive may be configured to wick into the stand-offs and then split producing adhesive deposits on the stand-offs. An integral release layer may be configured in a pattern wherein only a portion of the barrier layer is covered with the integral release layer or material. In some cases, a continuous integral release layer is processed such that only a portion of the integral release layer is configured to enable the adhesive to release. For example, an integral release layer may include a bonded portion and non-bonded portions, wherein the non-bonded portions are configured to fracture and stick to the adhesive to enable release of the adhesive from an adjacent layer. The non-bonded portions of the integral release layer may be configured in discrete areas and the percent coverage may be such that the adhesive is easily unspooled yet retains effective adhesion to a wall board. In an exemplary embodiment, the barrier composite includes stand-offs to promote drainage of water between the wall board and shingles or siding, for example. The integral release material or integral release layer may be coupled to the stand-offs. For example, the non-bonded integral release layer may be configured over the stand-offs and this integral release layer may be configur