(12) United States Patent
`Lionel
`
`USOO6901712B2
`(10) Patent No.:
`US 6,901,712 B2
`(45) Date of Patent:
`Jun. 7, 2005
`
`(54) SELF-ADHERING WAPOR PERMEABLE AIR
`AND MOSTURE BARRIER MEMBRANE
`
`(75) Inventor: Borenstein Lionel, Laval (CA)
`
`5,593,771. A * 1/1997 Lawless et al. .......... 428/317.3
`5,639,539 A * 6/1997 DeProspero et al. ..... 428/195.1
`5,953,883 A * 9/1999 Ojala ........................ 52/794.1
`5,972,147 A 10/1999 Janis
`5.998,015. A 12/1999 Furst .......................... 428/336
`6,083,613 A * 7/2000 Hayashi et al. .......... 428/315.7
`6,279.284 B1
`8/2001 Moras ......................... 52/408
`6,410,118 B1
`6/2002 Reicherts et al. ........... 428/141
`6,673,432 B2 * 1/2004 S. set al.
`... 428/301.1
`6,706,225 B2 * 3/2004 Cabrey ....................... 264/112
`2002/0173211 A1 11/2002 Kocinec et al. ............. 442/286
`FOREIGN PATENT DOCUMENTS
`861467 CA 1/1971
`935371 CA 10/1973
`O 238 014
`9/1987
`1344875
`9/2003
`
`CA
`CA
`EP
`EP
`
`OTHER PUBLICATIONS
`Bakelite, “The Dawning of Air Barrier Technology', pp. 1 to
`11.
`Tyvek by DuPont, “Why Use a Breathable Membrane?", pp.
`1 to 10.
`National Research Council Canada, Division of Building
`Research, “The Difference Between a Vapour Barrier and an
`Air Barrier” by R.L. Quirouette, BPN 54, Jul. 1985, ISSN
`0701-5216, pp. 1 to 13.
`* cited by examiner
`Primary Examiner Robert Canfield
`(74) Attorney, Agent, or Firm-Bachman & LaPointe, P.C.
`(57)
`ABSTRACT
`A Self-adhering air and moisture barrier sheet membrane for
`Structural Surfaces of buildings, which is permeable to the
`passage of water vapor, is comprised of a water vapor
`permeable sheet onto one Surface of which is applied an
`adhesive in a non-continuous film.
`
`24 Claims, 1 Drawing Sheet
`
`(73) Assignee: Bakor Inc., Lachine (CA)
`-
`(*) Notice:
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 32 days.
`(21) Appl. No.: 10/402,440
`1-1.
`(22) Filed:
`(65)
`
`9
`
`Mar. 28, 2003
`Prior Publication Data
`
`y
`
`- - -
`
`US 2004/0103608 A1 Jun. 3, 2004
`Foreign Application Priority Data
`(30)
`Dec. 3, 2002 (CA) ............................................. 2413550
`(51) Int. Cl." ............................... E04B 2/02; CO9J 7/02
`(52) U.S. Cl. .......................... 52/408; 156/71; 52/741.1;
`428/40.1; 428/41.8; 428/202; 428/220
`(58) Field of Search ................................. 52/408,741.1
`(56)
`References Cited
`U.S. PATENT DOCUMENTS
`
`4/1965 David
`3.532,589 A
`3,645,835 A * 2/1972 Hodgson ................. 428/195.1
`3,776.805 A * 12/1973 Hansen ...........
`... 428/35.9
`4,328,652. A
`5/1982 Naumovich, Jr. ............ 52/408
`4,680,913 A 7/1987 Geisen et al.
`4,929,303 A * 5/1990 Sheth ......................... 156/209
`5,091,235 A 2/1992 Vergano
`5,317,035 A 5/1994 Jacoby et al.
`5,374,477 A * 12/1994 Lawless et al. .......... 428/317.3
`5,398.471 A 3/1995 Spagnolo
`5,410,852 A * 5/1995 Edgar et al. .................. 52/408
`5,518,799 A * 5/1996 Finestone et al............ 428/137
`
`
`
`Louisiana-Pacific Corporation, Exhibit 1019
`IPR of U.S. Pat. No. 8,474,197
`Page 1
`
`

`

`U.S. Patent
`
`
`
`Jun. 7, 2005
`
`US 6,901,712 B2
`
`Louisiana-Pacific Corporation, Exhibit 1019
`IPR of U.S. Pat. No. 8,474,197
`Page 2
`
`

`

`1
`SELF-ADHERING WAPOR PERMEABLE AIR
`AND MOISTURE BARRIER MEMBRANE
`
`US 6,901,712 B2
`
`BACKGROUND OF THE INVENTION
`i) Field of the Invention
`This invention relates to a preformed sheet membrane,
`which can be used in the construction of buildings to control
`the movement of air and water through the building enve
`lope. The invention also relates to an assembly comprising
`a wall Structure which incorporates the membrane, and a
`method of assembling Such a wall Structure.
`ii) Description of Prior Art
`Moisture problems in walls have been attributed to two
`principal mechanisms: water vapor diffusion and air leak
`age. In recent years, control of air movement has become
`recognized as a major factor determining building
`performance, as measured by how well a building functions
`during its lifespan. Depending on local climate, air leakage
`through walls can result in excessive efflorescence, Spalling
`of masonry, frozen pipes, condensation and ice buildup in
`cavities, wet and dysfunctional insulation, mold growth as
`well as rain penetration, high energy costs and poor control
`of the building environment.
`Air leakage is the uncontrolled movement of air through
`the building envelope. This movement of air into a building
`(infiltration) and out of a building (exfiltration) is caused by
`preSSure differences produced by wind, Stack or chimney
`effect and fan pressurization. Air leakage may follow Such
`paths as holes or openings through the envelope, for
`example, cracks or joints between infill components and
`Structural elements or through porous materials. Such as
`concrete block and porous insulation materials.
`Older methods of building design often relied solely on
`the use of vapor barriers or retarders, Such as polyethylene
`film, to control water vapor movement in the building
`envelope. The vapor barrier retards the diffusion of water
`through the assembly of materials in a wall. The rate at
`which water vapor migrates or diffuses through a material
`depends on two factors: the difference between the water
`Vapor pressure in the air inside the building and that in the
`outside air, and the resistance that materials present to the
`migration of water by diffusion. A vapor barrier is a material
`that offers a higher resistance to the diffusion of water vapor
`than most other materials. Polyethylene film of Sufficient
`thickneSS is the material most commonly used for this
`purpose; however, other materials. Such as aluminum foil,
`Some paint products, Some insulation mastic adhesives and
`Some mastic coatings have been used as Vapor barriers. The
`moisture diffusion control property of a material is its water
`Vapor permeance. This is usually expressed as the weight of
`moisture that will diffuse through a given area over a
`Specified period of time at a unit vapor pressure difference.
`According to Canadian Standard CAN/CGSB-51.34-M86, a
`polyethylene sheet vapor barrier must have a maximum
`water vapor permeance of 15 ng/Pasm when tested in
`accordance with ASTM E96.
`For the vapor barrier to control condensation resulting
`from vapor diffusion, it must be placed on or near the warm
`Side of the insulation, which is normally the high vapor
`preSSure Side.
`Water vapor diffusion is one of the mechanisms by which
`water can be transported into a wall or roof cavity. The
`provision of a vapor barrier within the wall or roof assembly
`Satisfies only part of the requirement of controlling moisture
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`entry into building enclosures. The other mechanism, which
`is now considered to be far more significant, is air leakage.
`Both mechanisms may, however, operate at the same time.
`The principal function of the air barrier is to Stop outside
`air from entering the building through the walls, windows or
`roof, and inside air from exfiltrating through the building
`envelope to the outside. This applies whether the air is
`humid or dry, Since air leakage can result in problems other
`than the deposition of moisture in cavities. Exfiltrating air
`carries away heating and cooling energy, while incoming air
`may bring in pollution as well as disable a rain Screen wall
`System.
`Moisture-laden air passing through an insulated cavity
`with a vapor barrier may deposit much more moisture than
`would diffuse through the vapor barrier in the same period
`of time. Recent practices are increasingly recognizing the
`importance of incorporating an air barrier System in building
`designs.
`Materials and the method of assembly chosen to build an
`air barrier System must meet Several requirements if they are
`to perform the air leakage control function Successfully.
`1. There must be continuity throughout the building
`envelope. The air barrier material of the wall must be
`continuous with the air barrier material of the roof (e.g.,
`the roofing membrane). The air barrier material of the
`wall must be connected to the air barrier material of the
`window frame, etc.
`2. The air barrier System must be fastened to a Supporting
`Structure to resist a peak wind load, a Sustained Stack
`effect or pressurization from ventilation equipment; it
`must be Sufficiently rigid to resist deplacement.
`3. The air barrier system must be virtually air
`impermeable. According to the requirements of Part 5
`of the 1995 National Building Code of Canada, the
`material in the air barrier System intended to provide
`the principal resistance to air leakage is required to
`have an air leakage characteristic not greater than 0.02
`L/s.m’ measured at a pressure differential of 75 Pa.
`4. The air barrier assembly must be durable in the same
`Sense that the building is durable, and be made of
`materials that are known to have a long Service life or
`be positioned so that it may be serviced from time to
`time.
`A wall or roof assembly will require an air barrier and
`possibly also a vapor barrier. They may or may not be the
`Same material. But a combined System must meet the design
`requirements for both functions.
`A vapor barrier is usually placed on the warm Side of the
`insulation. It may also be positioned part way into the
`insulation but, for Satisfactory performance, it should be no
`further in than the point at which the temperature of the
`inside air drops to its dew point. While it is preferable that
`the air barrier System be placed on the warm Side of an
`insulated assembly, it is not an essential requirement as it is
`with the vapor barrier. The position of the air barrier in a
`wall or roof is more a matter of Suitable construction practice
`and the type of materials to be used. However, if this barrier
`is positioned on the outside of the insulation, consideration
`must be given to its water vapor permeability in case it
`should also act as a barrier to vapor which is on its way out
`from inside the wall assembly. This situation may be pre
`vented by choosing an air barrier material that is ten to
`twenty times or more permeable to water vapor diffusion
`than the vapor barrier material, in order to prevent high
`humidity conditions and the potential of mold development
`or condensation in the wall assembly. It is this situation that
`
`Louisiana-Pacific Corporation, Exhibit 1019
`IPR of U.S. Pat. No. 8,474,197
`Page 3
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`

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`3
`demonstrates the need for a water vapor permeable (or
`breathable) air barrier membrane.
`According to Canadian Standard CAN 2-51.32-M77, a
`breather type sheathing membrane must have a water vapor
`permeance of no less than 170 ng/Pasm' when tested in
`accordance with ASTM E96.
`In the current State of the art, there are products available
`both in preformed sheet form Supplied in rolls and in liquid
`form to be applied by bush, Spray or trowel that can Serve as
`air and moisture barrier membrane materials. AS examples
`of preformed sheet products, there may be mentioned Blue
`skin (trade-mark) SA Self-Adhesive Air & Vapor Barrier
`Membrane and Blueskin (trade-mark) TG Thermofusible
`Grade Air & Vapor Barrier Membrane as manufactured by
`Bakor Inc. These products are based on a polymer modified
`bitumen laminated to a polyethylene film Surface and, in the
`case of the Blueskin TG, reinforced with a non-woven
`fiberglass. Canadian Patent 1,261,239 describes an air bar
`rier membrane, consisting of a reinforcing Sheet of organic
`fibers coated on both sides with a bitumen binder, which can
`be applied using a torch or which can be Self-adhering and
`cold applied by pressure. Bituminous materials and poly
`ethylene films are known to be excellent vapor barriers.
`Materials Similar to the above are also used as water
`proofing membranes, which are normally installed on foun
`dation walls below ground level, as opposed to the air and
`moisture barriers discussed herein, which are normally
`installed on exterior walls above ground, and roofs, to
`protect against the infiltration and exfiltration of air and the
`infiltration of wind driven rain. Some Such materials are
`described in Canadian Patents 861,467 and 935,371.
`As examples of liquid applied air and moisture barrier
`products, there may be mentioned Air-Bloc 06 (trade-mark)
`Elastomeric Liquid Air & Vapor Barrier and Air-Bloc 31
`(trade-mark) Liquid Emulsion Vapor Permeable Air Barrier
`Membrane, as manufactured by Bakor Inc. Although the
`technology exists for a vapor permeable air and moisture
`barrier membrane of the liquid applied type, there does not
`currently exist a preformed sheet membrane which entirely
`meets the practical requirements for providing an air and
`moisture barrier System as previously outlined. Liquid
`applied membranes themselves need to have preformed
`sheets incorporated into the air and moisture barrier System
`to tie the liquid applied membrane into beams, window and
`door frames and to connect the roof membrane in order to
`provide continuity of the System. Sheet membranes are often
`preferred over liquid applied membranes because sheet
`membranes come with factory-controlled thickness.
`Some preformed sheet membrane products offer a partial
`Solution to providing a water vapor permeable or breathable
`air barrier System. One Such product is Tyvek (trade-mark)
`Spunbonded polyolefin sheet as manufactured and Sold by
`DuPont under U.S. Pat. No. 3,532,589. This type of product
`presents a number of difficulties in achieving an air barrier
`System in that multiple accessory products are required in
`order to create a continuous plane of air tightness throughout
`the building envelope. These accessories include mechanical
`fasteners, nails or Screws, with large diameter metal or
`plastic plates or washers to Secure the membrane, Seaming
`tape to tape the joints of the membrane and flexible flashing
`for all transition areas Such as tie-ins to window frames. The
`use of a tape, and multiple mechanical fasteners which
`puncture the membrane compromise the integrity of the
`System.
`In addition, further difficulties occur when attempting to
`mechanically fasten this type of product on commercial
`buildings over Such Substrates as concrete block as opposed
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`US 6,901,712 B2
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`to wood frame housing. Further, because this type of mem
`brane is not fully adhered to the substrate, it allows air to
`move freely behind it, to find an opening or defect in the
`membrane through which it can escape.
`A potential Solution to the deficiencies exhibited by
`current breathable sheet materials would appear to be in the
`use of an adhesive, applied to one side of the sheet, to enable
`the sheet to be self-adhered to the Substrates, thus eliminat
`ing the need for mechanical fastenerS and tapes. However,
`adhesive films as normally applied tend to Substantially
`reduce the water vapor permeance of the sheets.
`SUMMARY OF THE INVENTION
`It is an object of the invention to provide a preformed sheet
`air barrier membrane which is permeable to water vapor and
`which can be adhered to a Substrate, Substantially over its
`entire area, by Virtue of an adhesive deposited on one side
`of the sheet.
`A further object of the invention is to provide a pattern for
`depositing the adhesive on the membrane Such that the
`lateral movement of air between the membrane and the
`Substrate or through lap joints of membrane Sections is
`restricted.
`A still further object of the invention is to provide a water
`Vapor permeable, air barrier sheet membrane which can be
`installed without the use of mechanical fasteners, nails,
`Screws or tapes to provide an air barrier System with a
`continuous plane of air tightness.
`Another object of this invention is to provide an adhesive
`backed water vapor permeable sheet membrane that can
`perform as a barrier to the infiltration of liquid or bulk water
`as from wind driven rain, when used in wall and roof
`assemblies.
`In accordance with one aspect of this invention, there is
`provided a membrane permeable to water vapor, on one side
`of which is deposited an adhesive in a non-continuous film
`leaving Zones of uncoated membrane, thereby permitting the
`diffusion of water vapor through the membrane at the
`uncoated Zones.
`In accordance with another aspect of this invention, the
`adhesive is deposited in a pattern on the membrane Such that
`the adhesive interSects or connects in a manner to avoid
`providing channels through which air can laterally migrate
`when the membrane is bonded to a Substrate or overlapped
`to provide a lap joint.
`In accordance with yet another aspect of the invention, the
`membrane, although permeable to water vapor, is imperme
`able to liquid or bulk water and can thus perform as an
`adhesive backed moisture barrier which is permeable to
`water vapor.
`In accordance with a further aspect of the invention, there
`is provided a Self-adhering, water vapor permeable, air and
`moisture barrier sheet for Structural Surfaces of buildings,
`comprising (i) an air and moisture barrier membrane which
`is water vapor permeable, and (ii) has an adhesive applied to
`one Side of the water vapor permeable membrane in a
`non-continuous film.
`In accordance with a particular embodiment of the
`invention, there is provided a Self-adhering sheet for Struc
`tural Surfaces, comprising, (a) an air and moisture barrier
`membrane having opposed first and Second faces, Said
`membrane being water vapor permeable, and (b) an adhesive
`applied to Said Second face in a non-continuous film to
`define a plurality of Spaced apart non-adhesive coated Zones
`Surrounded by an adhesive coated Zone.
`In yet another aspect of the invention, there is provided an
`article of manufacture comprising a Self-adhering sheet of
`the invention having a Strippable release sheet removably
`adhered to Said Second face by Said non-continuous adhesive
`film.
`
`Louisiana-Pacific Corporation, Exhibit 1019
`IPR of U.S. Pat. No. 8,474,197
`Page 4
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`

`

`S
`In Still another aspect of the invention, there is provided
`an assembly comprising a hollow wall Structure having an
`external wall member and an opposed internal wall member,
`a vapor impermeable barrier sheet disposed within Said
`Structure adjacent Said internal wall member, and a Self
`adhesive sheet, of the invention, Spaced from Said barrier
`sheet and disposed between Said barrier sheet and Said
`external wall member.
`In Still another aspect of the invention, there is provided
`a method of assembling a wall Structure comprising, in any
`Sequence, providing an internal wall member, disposing a
`Vapor impermeable barrier sheet adjacent an exterior face of
`Said internal wall member, disposing a Self-adhering sheet,
`of the invention, externally of Said barrier Sheet and Spaced
`apart therefrom, and disposing an external wall member
`externally of Said Self-adhering sheet and Spaced therefrom.
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`i) Vapor Permeable Membrane
`The vapor permeable membrane of the invention is a
`flexible sheet or film normally supplied in roll form, which
`is permeable to the passage of water in vapor form. The
`sheet or film may be microporous, microperforated or Some
`other type of vapor permeable sheet or film.
`A microporous sheet or film is a non-perforated continu
`ous microfibre web with microscopic pores large enough for
`moisture vapor to pass through, but Small enough to resist air
`and liquid water. Microperforated membranes depend on
`mechanical pin-perforations and/or film laminations to build
`in properties.
`While both of the abovementioned types of sheet or film
`are permeable to water vapor, a sheet or film of the
`microporous type is preferred as this type is less permeable
`to the passage of water or moisture in liquid or bulk form.
`Suitable microporous sheets or films are spunbonded or
`fibrous bonded polyolefin as described in U.S. Pat. Nos.
`3,532,589 and 5,972,147, preferred polyolefins are polyeth
`ylene and polypropylene, one Such microporous sheet is
`available commercially under the trade-mark Tyvek; other
`Suitable microporous sheets include oriented polymeric
`films as described in U.S. Pat. No. 5,317,035, and which
`comprise ethylene-propylene block copolymers; one Such
`film is commercially available as Aptra (trade-mark). The
`sheets or films may be reinforced with various types of Scrim
`materials or may be laminated to other vapor permeable
`sheets or films, Such as non-woven polypropylene or non
`woven polyester for the purpose of improving Strength and
`other physical properties.
`In general, the membrane will typically have a thickneSS
`of 0.001 to 0.04, preferably 0.001 to 0.025 inches.
`ii) Adhesive
`The adhesive can be a hot melt adhesive, Solvent based
`adhesive, water based adhesive or of other types such as UV
`cured polymer. The applied adhesive is preferably tacky, i.e.
`-Sticky and pressure Sensitive. Suitable hot melt adhesives
`may contain Such ingredients as polymerS Such as butyl
`rubber, Styrene-butadiene-styrene (SBS), Styrene-isoprene
`styrene (SIS), styrene butadiene (SB), styrene-ethylene
`butadiene-styrene (SEBS) and ethylenevinylacetate (EVA);
`resins Such as those of the hydrocarbon and roSin types,
`natural and petroleum waxes, oils, bitumen and others.
`Solvent-based adhesives may contain ingredients Such as
`those listed above, dissolved or dispersed in a Solvent
`vehicle. Water based adhesives would normally be based on
`emulsions of polymeric materials. Suitable polymeric mate
`rials would include vinyl acetate and acrylic polymers and
`copolymerS Such as vinyl acetate acrylic, ethylene Vinyl
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`acetate as well as Styrene acrylic, vinyl chloride acrylic,
`Vinyl versatate and others.
`From a production Standpoint, the preferred adhesives are
`of the hot melt type which are simply melted for application
`and need not emit Solvent which is an environmental pol
`lutant and may require re-condensation. Water based adhe
`Sives have the disadvantage that they generally require the
`additional use of drying ovens or heat lamps to evaporate the
`Water.
`The adhesive may Suitably be applied at a thickness of
`0.001 inches to 0.1 inch, but is preferably applied at a
`thickness of 0.003 inches to 0.025 inches and most prefer
`ably at a thickness of 0.005 inches to 0.02 inches.
`The adhesive may be protected with a Strippable release
`sheet or liner to enable packaging in rolls. Suitable release
`sheets are paper sheet, having a Silicone release Surface
`coating and Some treated plastic films.
`iii) Adhesive Pattern
`To retain an essential level of water vapor permeance in
`the adhesive coated membrane, the adhesive is applied to the
`Vapor permeable membrane in a non-continuous film in
`order to leave parts, or spots or Zones of the sheet uncoated
`with adhesive.
`In order to prevent the lateral movement of air between
`the membrane and the Substrate to which it is bonded, and
`through lap joints of the membrane, the adhesive coated
`areas of the membrane can be made to interSect to isolate the
`uncoated areas, thereby eliminating channels through which
`air can laterally move. This can be achieved by any number
`of patterns, Such as interSecting circles with adhesive free
`centers, interSecting Squares or rectangles of adhesive, inter
`Secting Strips in a checkered pattern, etc.
`In general, the adhesive film forms an adhesive Sea on the
`membrane Surface, with a multitude of membrane islands,
`surrounded by but not covered by the adhesive sea.
`The adhesive may suitably be applied so as to cover 5%
`to 99% of the area of one side of the membrane, but is
`preferably applied to cover between 25% and 90% of the
`area, and most preferably between 50% and 80% of the area,
`to obtain the optimum balance of adhesion and vapor
`permeance in the sheet.
`iv) Primer
`AS is common with other types of Self-adhering
`membranes, the use of a liquid primer coating may Some
`times be recommended to improve adhesion of the mem
`brane to Some Substrates. In the case of a vapor permeable
`membrane, the primer should be Selected from certain
`materials or applied at a reduced rate or in a manner Such
`that the breathability of the assembly is not compromised.
`v) Vapor Impermeable Barrier Sheet
`The vapor permeable membrane sheet of the invention is
`typically employed in a building Structure, especially a wall
`Structure, in conjunction with a vapor impermeable barrier
`sheet. A preferred sheet is a polyethylene sheet, as known in
`the art, having a water vapor permeance of not more than 15
`ng/Pasm (ASTM E96).
`Such a sheet may be considered a vapor retarder, Since it
`is not completely impermeable to water vapor.
`Typically, the barrier sheet has a thickness of 0.001 to
`0.008 inches, more usually 0.002 to 0.006 inches.
`BRIEF DESCRIPTION OF DRAWINGS
`FIG. 1 is a schematic view of a membrane assembly of the
`invention; and
`FIG. 2 is a Schematic cross-section of a wall Structure
`assembly of the invention.
`DESCRIPTION OF PREFERRED
`EMBODIMENTS WITH REFERENCE TO THE
`DRAWINGS
`With further reference to FIG. 1, a membrane assembly 10
`includes a Self-adhering sheet 12 and a release liner 14.
`
`Louisiana-Pacific Corporation, Exhibit 1019
`IPR of U.S. Pat. No. 8,474,197
`Page 5
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`7
`Sheet 12 comprises a vapor permeable membrane 16,
`having on one side a non-continuous adhesive film. Mem
`brane 16 is impermeable to air and water and thus provides
`a barrier to air and water.
`A plurality of Zones 20 of membrane 16 are defined by the
`film 18. Essentially, the Zones 20 form islands of uncoated
`membrane in the Sea of adhesive film 18.
`Sheet 12 adheres to release liner 14 by means of adhesive
`film 18.
`Release liner 14 has a release Surface, for example, a
`Silicone Surface 22, which permits ready Separation of sheet
`12 and liner 14 to expose adhesive film 18, for adhesion to
`a Substrate in use.
`With further reference to FIG. 2, a wall structure assembly
`30 includes an interior gypsum wall panel 32 and an exterior
`wall structure 40.
`A vapor impermeable barrier sheet 34, for example of
`polyethylene, is mounted adjacent interior gypsum wall
`panel 32.
`A Second or exterior gypsum wall panel 36 is disposed in
`Spaced relationship with interior gypsum wall panel 32,
`between panel 32 and the external wall structure 40.
`Insulation 38 is disposed between gypsum wall panel 36
`and barrier sheet 34.
`A self-adhering sheet 46, which will typically be of the
`form of sheet 12 of FIG. 1, is adhered to gypsum wall panel
`36.
`External wall structure 40 may, for example, comprise
`bricks 42 and mortar 44.
`Typically, the wall structure assembly 30 may include an
`air cavity 48 between external wall structure 40 and sheet
`46, and optionally, there may be further insulation (not
`shown) in this cavity.
`It will be understood that the sheet 46 or 12 adheres to the
`gypsum wall panel 36 by means of the adhesive film 18.
`EXAMPLE
`The invention is further illustrated by the example and
`comparative tests below.
`A Self-adhering sheet membrane was constructed by
`45
`applying a hot melt pressure Sensitive adhesive to a mem
`brane comprising Pro/Shield (trade-mark) 2, a product of
`Kappler Protective Apparel & Fabrics. Pro/Shield is a com
`posite membrane in which one ply of light non-woven
`polypropylene mat is laminated by heat and pressure to one
`ply of a microporous film available under the trade-mark
`APTRA, a product of Amoco Fabrics & Fibers Company.
`The typical properties of Aptra microporous film are given
`in Table 1 while those of Pro/Shield 2 are given in Table 2.
`The adhesive was applied using a coater, and was applied
`to the non-woven polypropylene Side of the composite
`membrane at a rate of 3 OZ. per Square yard, at a thickneSS
`of 0.01 inches, covering approximately 75% of the surface
`area of the membrane. The adhesive pattern was Such that
`circular shaped adhesive-free spots or Zones of approxi
`mately 0.05 inches in diameter were surrounded by the
`adhesive matrix. The adhesive layer was protected by cov
`ering with a sheet of removable Siliconized release paper.
`The product was produced in rolls of approximately 60
`inches wide by 100 feet in length, which could be further slit
`into more convenient widths for various applications.
`
`25
`
`35
`
`40
`
`50
`
`55
`
`60
`
`65
`
`US 6,901,712 B2
`
`15
`
`8
`Water vapor permeance tests were conducted in accor
`dance with ASTM E96, on the above self-adhering sheet
`(A) and on a similarly prepared Sample of sheet (B) on
`which the hot melt adhesive was applied in an even, con
`tinuous film at the Same rate of 3 oz. per Square yard. The
`following results were obtained:
`
`Sheet A
`Sheet B
`
`2370 ng/Pa m’ s
`55 ng/Pa m’ s
`
`These results show that Sheet A, which had a non
`continuous adhesive film, exhibited a water vapor per
`meance greater than 170 ng/Pasm, thus meeting the
`requirements of Canadian Standard CAN2-51.32-M77 for a
`breather type membrane, while Sheet B with a continuous
`film of adhesive applied at the same rate, exhibited a
`Significantly lower water vapor permeance and did not meet
`the Standard.
`
`Sheet A was tested for air leakage in accordance with
`Bodycote Materials Testing Procedure #93-J53-SP-013A.
`The Sheet was applied by hand preSSure to the prepared
`surface of a 1220 mm by 1220 mm by 152 mm thick
`concrete block wall, incorporating a lap joint averaging 188
`mm down the center. The air leakage test was carried out in
`accordance with ASTM E 283-91 (1999) “Standard Test
`Method for Determining the Rate of Air Leakage Through
`Exterior Windows, Curtain Walls and Doors Under Speci
`fied Pressure Differences Across the Specimen”. The air
`leakage rate at a negative pressure differential of 75 Pa was
`determined to be 0.010 L/sm'. This value is in compliance
`with the 1995 National Building Code of Canada require
`ment of 0.02 L/sm' maximum.
`
`TABLE I
`
`APTRATM FILM TYPICAL PROPERTIES
`
`PROPERTY
`Basis Weight
`Thickness
`Grab Tensile Strength
`
`MD
`TD
`Grab Elongation
`
`MD
`TD
`1" Strip Tensile Strength
`
`MD
`TD
`1" Strip Elongation
`
`MD
`TD
`Mullen Burst Strength
`CPAI Hydrostatic
`Resistance
`Gurley Densometer
`Porosity
`Water Vapor
`Transmission Rate
`
`UNITS
`
`English
`0.75 Oz/yd’
`1.5 mills
`
`SI
`Test Methods
`25 g/m· ASTM D-75
`38.u.
`ASTM D-75
`
`13 lbs
`12 lbs
`
`59 N ASTM D-75
`53 N.
`
`100%
`70%
`
`ASTM D-75
`
`4.0 lbs
`3.5 lbs
`
`18 N. ASTM D-75
`16 N
`
`120%
`75%
`
`ASTM D-75
`
`68 psi
`>50 in
`
`470 kPa ASTM D-75
`>12.5 kPa ASTM D-75
`
`900 s/100 cc
`
`AFFC PTO76
`
`5000 g/m/24 h ASTM E-96,
`method E
`
`Louisiana-Pacific Corporation, Exhibit 1019
`IPR of U.S. Pat. No. 8,474,197
`Page 6
`
`

`

`US 6,901,712 B2
`
`10
`
`9
`
`TABLE 2
`
`Prof Shield (R) 2 TYPICAL PROPERTIES
`
`Physical Property
`Basis Weight
`Grab Tensile Strength
`
`Test Method
`ASTM D751
`ASTM D751
`
`Puncture/Propagation Tear
`
`ASTM D2582
`
`ASTM D3787
`Ball Burst
`Hydrostatic Water Resistance ASTM D751
`PROCEDUREA
`Moisture Vapor Transmission ASTM E-96
`Rate
`PROCEDURED
`(g/m/24 hrs)
`Surface Resistivity (ohm/cm) ASTM D257
`
`Results
`Imperial
`1.7 oz/yd?
`MD 30 lbs
`CD 26 lbs
`MD 6.4 lbs
`CD 9.3 Ibs
`26 lbs.
`17.7 psi
`
`Results
`Metric
`57.6 g/m?
`MD 133 N.
`CD 115 M
`MD 28.4 N
`CD 413 N
`115 N
`122.0 kPa
`
`1481.5
`
`1481.5
`
`1011
`
`1011
`
`25
`
`What is claimed is:
`1. A Self-adhering, water vapor permeable, air and mois
`ture barrier sheet for Structural Surfaces of buildings, com
`prising
`i) an air and moisture barrier membrane which is water
`Vapor permeable, and
`ii) an adhesive applied to one side of the water vapor
`permeable membrane in a non-continuous film.
`2. A sheet according to claim 1, wherein the membrane
`Vapor is a microporous film or a composite thereof.
`3. A sheet according to claim 2, wherein the microporous
`film is an oriented polymeric film or a composite thereof.
`4. A sheet according to claim 2, wherein the microporous
`film is a polyolefin film or a composite thereof.
`5. A sheet according to claim 2, wherein the microporous
`film is a polypropylene film or a composite thereof.
`6. A sheet according to claim 2, wherein the microporous
`film is a spun bonded polyolefin or a composite thereof.
`7. A sheet according to claim 1, wherein the adhesive is
`a hot melt adhesive.
`8. A sheet according to claim 7, wherein the adhesive is
`applied at a thickness of 0.001 inches to 0.1 inches.
`9. A sheet according to claim 8, wherein Said thickneSS is
`0.003 inches to 0.025 inches.
`10. A sheet according to claim 8, wherein said thickness
`is 0.005 inches to 0.02 inches.
`11. A sh