Self-adhesive article

Abstract

A self-adhesive article comprising (i) a weather resistant barrier layer comprising a first non-woven fabric attached to a first vapor permeable and liquid impermeable (VPLI) film, (ii) an adhesive layer comprising an adhesive composition wherein the adhesive layer is positioned adjacent the first non-woven fabric, and wherein the first nonwoven fabric is located between the first VPLI film and the adhesive layer; and (iii) a release liner positioned adjacent the adhesive layer, wherein the adhesive layer is between the first nonwoven fabric and the release liner.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 USC §119(e) to U.S. patent application No. 63 / 444,519, filed on February 9, 2023, the entire disclosure of which is hereby expressly incorporated herein by reference. Technical Field

[0003] Embodiments of the presently disclosed invention are generally directed to self-adhesive articles comprising (i) a weatherable barrier layer comprising a first nonwoven fabric attached to a first vapor permeable and liquid impermeable (VPLI) film, (ii) an adhesive layer comprising an adhesive composition; and (iii) a release liner positioned adjacent the adhesive layer, wherein the release liner can be peeled back to expose the adhesive layer prior to securing the self-adhesive article to a surface. Background Art

[0004] Over time, moisture can accumulate within a building's structure, leading to premature deterioration and damage. This problem is particularly common in regions with high humidity and rainfall, such as the Pacific Northwest. In this regard, housewrap material (housewap) is used to wrap the exterior surfaces of a house or other building during the construction process, more specifically, after the attachment of the covering and before the installation of the siding / cladding. Housewrap material is typically provided in roll form, from which sheets of appropriate lengths can be conveniently dispensed (e.g., unrolled) and then separated (e.g., cut, torn, etc.) from the rest of the roll.

[0005] Housewrap materials typically include a barrier layer that provides a moisture barrier against external water or moisture while also allowing water vapor to pass through from within the shell. This restricts the passage of liquid water and air (e.g., rain and wind) into the building structure, thereby preventing water damage to insulation and structural components and minimizing air movement within the walls. At the same time, water vapor that enters the walls from within the building structure can escape so that it does not condense within the walls and potentially damage insulation and structural components.

[0006] Multiple sheets of housewrap material are required to cover a house or other building. For example, long strips of sheet material can be dispensed from a roll and then hung vertically along the building (like wallpaper) or horizontally across the building. The housewrap material can be attached to the sheathing using staples, tacks, or plastic washers. Horizontal and vertical seams (or seams) will exist between adjacent sheets of housewrap material, and these seams can be taped or otherwise sealed to make the seams airtight and watertight. However, such mechanical attachment means can negatively impact the effectiveness of the housewrap material due to the formation of holes associated with mechanical fasteners (e.g., staples, nails, etc.) through the housewrap material.

[0007] Thus, there remains at least a need in the art for a self-adhesive article, such as a housewrap material, that does not require the use of mechanical fasteners for attachment to the building of interest. Summary of the Invention

[0008] One or more embodiments of the present invention can solve one or more of the above problems. Certain embodiments of the present invention provide a self-adhesive article, such as a housewrap material, comprising: (i) a weatherable barrier layer comprising a first nonwoven fabric attached to a first vapor permeable and liquid impermeable (VPLI) film, (ii) an adhesive layer comprising an adhesive composition, wherein the adhesive layer can be positioned adjacent to the first nonwoven fabric, and wherein the first nonwoven fabric is positioned between the first VPLI film and the adhesive layer; and (iii) a release liner positioned adjacent to the adhesive layer, wherein the adhesive layer is positioned between the first nonwoven fabric and the release liner.

[0009] In another aspect, certain embodiments of the present invention provide a method for preparing a self-adhesive article, such as a housewrap material. The method can include the following steps: (i) melt-extruding a first vapor-permeable and liquid-impermeable (VPLI) film directly onto a first surface of a first nonwoven fabric to form a weatherable barrier layer or providing a weatherable barrier layer comprising a first VPLI melt-extruded onto a first nonwoven fabric; (ii) depositing an adhesive layer comprising an adhesive composition directly onto a second surface of the first nonwoven fabric, wherein the first nonwoven fabric is located between the first VPLI film and the adhesive layer; and (iii) applying a release liner to and in contact with the adhesive layer, wherein the adhesive layer is located between the first nonwoven fabric and the release liner to form a self-adhesive article.

[0010] In another aspect, certain embodiments of the present invention provide building assemblies, wherein the building assembly can include an interior covering member, an exterior building material, and a self-adhesive article, such as those described and disclosed herein, wherein the release liner has been peeled away (e.g., peeled) and the adhesive layer bonds the weatherable barrier layer to the interior covering member. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Throughout the text, like reference numerals refer to like elements, wherein:

[0012] Figure 1 A self-adhesive article comprising a discontinuous adhesive layer sandwiched between a release liner and a first nonwoven fabric according to certain embodiments of the present invention is shown;

[0013] Figure 2 A self-adhesive article comprising a continuous adhesive layer sandwiched between a release liner and a first nonwoven fabric according to certain embodiments of the present invention is shown;

[0014] Figure 3 shows a discontinuous adhesive layer according to certain embodiments of the present invention, the discontinuous adhesive layer comprising a plurality of discrete regions of an adhesive composition and a plurality of discrete regions without any adhesive composition;

[0015] Figure 4 shows another discontinuous adhesive layer including a continuous area devoid of any adhesive composition according to certain embodiments of the present invention;

[0016] Figure 5 shows another discontinuous adhesive layer including a continuous area devoid of any adhesive composition according to certain embodiments of the present invention;

[0017] Figure 6 Another discontinuous adhesive layer comprising a plurality of individual islands without any adhesive composition is shown according to certain embodiments of the present invention;

[0018] Figure 7 shows another discontinuous adhesive layer including a continuous area devoid of any adhesive composition according to certain embodiments of the present invention;

[0019] Figure 8 A discontinuous meltblown layer is shown, comprising a plurality of meltblown streams and meltblown ropes deposited on a first VPLI film;

[0020] Figure 9 shows a side view of a discontinuous meltblown layer comprising a plurality of meltblown streams and meltblown ropes deposited on a first VPLI film;

[0021] Figure 10 shows a cut-away side view of a building assembly according to certain embodiments of the present invention;

[0022] Figure 11 Some embodiments of the present invention are shown Figure 10 a portion of the building assembly shown; and

[0023] Figure 12 A discontinuous adhesive layer according to certain embodiments of the present invention is shown. DETAILED DESCRIPTION

[0024] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0025] The present invention generally relates to a self-adhesive article, such as a house wrap material (housewrap), which includes a weather-resistant barrier layer comprising at least a first VPLI film attached to a first nonwoven fabric. The weather-resistant barrier layer can prevent a large amount of liquid and air from the external environment from entering or passing through, while also allowing water vapor to pass through to prevent unwanted moisture from accumulating under the self-adhesive article when installed on a building. The self-adhesive article can include a release liner that can be peeled off to expose or expose an adhesive layer, which can be a discontinuous layer or a continuous layer of an adhesive composition. After removing at least a portion of the release liner, the self-adhesive article can be bonded to a building structure through the exposed adhesive layer. In this regard, a building can be wrapped (e.g., encapsulated) by multiple such self-adhesive articles without the need for mechanical fasteners, such as nails and staples, which can impart holes in the weather-resistant barrier assembly of the self-adhesive article. According to certain embodiments of the present invention, the self-adhesive article can simultaneously provide a series of improved properties, such as increased tensile strength and improved cold bendability.

[0026] The term "substantially" or "essentially" may encompass the total amount specified according to certain embodiments of the invention, or largely but not the total amount specified (e.g., 95%, 96%, 97%, 98% or 99% of the total amount specified) according to other embodiments of the invention.

[0027] The terms "polymer" or "polymeric", as used interchangeably herein, may include homopolymers, copolymers, such as block, graft, random and alternating copolymers, terpolymers, and the like, and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the terms "polymer" or "polymeric" shall include all possible structural isomers; stereoisomers, including but not limited to geometric isomers, optical isomers, or enantiomers; and / or any chiral molecular configuration of such polymer or polymeric material. These configurations include but are not limited to isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The terms "polymer" or "polymeric" shall also include polymers made from various catalyst systems, including but not limited to Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. According to certain embodiments of the present invention, the terms "polymer" or "polymeric" shall also include polymers produced by fermentation methods or of biological origin.

[0028] As used herein, the terms "nonwoven material" and "nonwoven web" may include a web having a structure of individual fibers, filaments and / or lines that are interwoven but not in a repetitive manner as identifiable in knitted or woven fabrics. According to certain embodiments of the present invention, nonwoven fabrics or webs may be formed by any conventional method known in the art, such as meltblown, spunbond, needlepunch, hydroentanglement, airlaid, and bonded carding. As used herein, a "nonwoven web" may include multiple individual fibers that have not undergone a consolidation process. In some cases, a "nonwoven web" may include multiple layers, such as one or more spunbond layers and / or one or more meltblown layers. For example, a "nonwoven web" may include a spunbond-meltblown-spunbond structure.

[0029] As used herein, the terms "fabric" and "nonwoven fabric" may include fiber webs in which a plurality of fibers are mechanically entangled or interconnected, fused together, and / or chemically bonded together. For example, a nonwoven fiber web of individually laid fibers may be subjected to a bonding or consolidation process to bond at least a portion of the individual fibers together to form a bonded (e.g., united) fiber web of interconnected fibers.

[0030] As used herein, the terms "consolidated" and "consolidation" may include bringing at least a portion of the fibers of a nonwoven web together so that they are brought closer together or attached thereto (e.g., thermally melted together, chemically bonded together, and / or mechanically entangled) to form one or more bond sites that act to increase resistance to external forces (e.g., wear and tension) compared to an unconsolidated web. For example, one or more bond sites may include discrete or localized areas of the web material that have been softened or melted and, optionally, subsequently or simultaneously, compressed to form discrete or localized deformations in the web material. Additionally, the term "consolidated" may include an entire nonwoven web that has been processed so that at least a portion of the fibers are brought closer together or attached thereto (e.g., thermally melted together, chemically bonded together, and / or mechanically entangled), such as by thermal bonding or mechanical entanglement (e.g., hydraulic entanglement), to name a few examples. According to certain embodiments of the present invention, such a web may be considered a "consolidated nonwoven material," a "nonwoven fabric," or simply a "fabric."

[0031] As used herein, the term "spunbond" may include fibers formed by extruding a molten thermoplastic material as filaments from a plurality of thin, generally circular capillaries of a spinneret, and then rapidly reducing the diameter of the extruded filaments. According to embodiments of the present invention, spunbond fibers are generally not sticky when deposited onto a collecting surface and may be generally continuous as disclosed and described herein. Note that the spunbond materials used in certain composite materials of the present invention may include nonwovens described in the literature. Spunbond fibers, for example, include continuous fibers.

[0032] As used herein, the term "continuous fibers" refers to fibers that are not cut from their original length prior to forming a nonwoven web or nonwoven fabric. The average length of the continuous fibers may be from greater than about 15 centimeters to greater than one meter, and may be up to the length of the formed web or fabric. For example, the continuous fibers used herein may include fibers wherein the fiber length is at least 1,000 times the average fiber diameter, such as at least about 5,000, 10,000, 50,000, or 100,000 times the average fiber diameter.

[0033] According to certain embodiments of the present invention, the term "meltblown" as used herein may include fibers formed by extruding a molten thermoplastic material as a molten thread or filament through a plurality of fine die capillaries into a converging high-speed (usually hot) gas (e.g., air) stream, the gas stream thinning the filaments of the molten thermoplastic material to reduce their diameter, which may be a microfiber diameter. According to embodiments of the present invention, the die capillaries may be circular. The meltblown fibers are then carried by the high-speed air stream and deposited on a collecting surface to form a web of randomly distributed meltblown fibers. The meltblown fibers may include microfibers that may be continuous or discontinuous and are typically tacky when deposited on a collecting surface. However, the length of the meltblown fibers is shorter than that of the spunbond fibers.

[0034] As used herein, the term "meltblown shot" may include a rough, non-uniform, or discontinuous layer applied during a meltblowing process intentionally operated to produce random globules of polymer interconnected with strands. Furthermore, the term "meltblown rope" as used herein may also include a rough, non-uniform, or discontinuous layer applied during a meltblowing process intentionally operated to produce random "ropes" or bundles of polymer interconnected with strands. A meltblown rope differs from a meltblown stream in that a meltblown rope can be more elongated and / or narrower than a meltblown stream. Both a meltblown rope and / or a meltblown stream can include irregularly shaped fibers, fillers, or particles. In this regard, for example, a meltblown rope and / or a meltblown stream can include fibers, fillers, particles, or globules having a non-circular cross-section. A meltblown rope and / or a meltblown stream can be randomly and irregularly distributed on a surface. For example, a meltblown rope and / or a meltblown stream can extend along a random path and can intersect and / or cross at random locations. However, the meltblown ropes and / or meltblown streams may not intersect or cross at all.

[0035] As used herein, the term "discontinuous" may include a layer of meltblown particles and / or meltblown ropes. The meltblown streams and / or meltblown ropes may be isolated from one another, although some meltblown streams and / or meltblown ropes may be connected to one another. In this regard, a discontinuous meltblown layer deposited on an underlying material (e.g., a weatherable barrier layer) will not cover 100% of the surface area of ​​the underlying material. As used herein, the term "non-uniform" may include a continuous layer of meltblown fibers having a varying thickness throughout and including three-dimensional portions, including meltblown streams, meltblown ropes, and / or the like.

[0036] As used herein, the term "film" may include one or more polymeric or elastomeric layers made using a film extrusion process such as a cast film or blown film extrusion process. The term may also include films that have been rendered microporous by mixing a polymer and / or elastomer with a filler, forming a film from the mixture, and optionally stretching the film.

[0037] As used herein, the term "microporous" membrane may include films or membranes having a narrow pore size distribution in the submicron range of 1.0 to 10 microns. Microporous membranes can be prepared by a number of methods, including (a) dissolving a polymer in a solution and then extracting the solvent with water vapor, (b) stretching a crystallizable polymer, which results in micro-sized tears, and (c) stretching a mineral-filled polyolefin membrane. Polymers used for microporous membranes include PTFE, polyolefins, polyurethanes, polyamides, and polyesters.

[0038] As used herein, the term "monolithic" membrane may include any continuous membrane that is substantially free of or free of pores. In certain alternative embodiments of the present invention, a "monolithic" membrane may contain a pore structure that is less than that found in a microporous membrane. According to certain non-limiting exemplary embodiments of the present invention, a monolithic membrane may act as a barrier to liquids and particulate matter, but allow water vapor to pass through.

[0039] As used herein, the term "weather resistant barrier" may include materials, such as sheet materials, that may function as an air barrier to generally prevent air infiltration, thereby mitigating drafts, and provide bulk water resistance, thereby helping to prevent bulk water from passing therethrough. In certain embodiments, a "weather resistant barrier," as used herein, may also provide moderate to high vapor permeability to allow water that may be "trapped" behind the weather resistant barrier to evaporate to prevent mold formation. Such materials may generally be marketed as "house wrap." According to certain embodiments of the present invention, the weather resistant barrier may include any currently or future commercially available house wrap material. Examples of weather resistant barriers currently marketed as home wrap include, but are not limited to, (produced by Berry Global of Evansville, India), Lining or cladding material (DuPont TM ), Air- (produced by Berry Global of Evansville, India), Air- Value (produced by Berry Global of Evansville, India), Air- XL (produced by Berry Global of Evansville, India) and CertaWrap TM (CertainTeed Corporation, USA). In this regard, the structure of the weatherable barrier layer can vary, including microporous membranes, monolithic membranes, fibrous structures (e.g., woven and / or nonwoven materials), and composite materials including fibrous structures combined with membranes, such as In certain embodiments of the present invention, the weather resistant barrier layer may be free of any film, e.g. For example, Utilizing fine high-density polyethylene (HDPE) spun fibers, these fibers are fused together to form a uniform web with numerous extremely small pores that resist substantial water and air penetration while allowing moisture vapor to pass through.

[0040] As used herein, the term "layer" may include generally identifiable groups of similar material types and / or functions that exist in the XY plane.

[0041] As used herein, the term "machine direction or longitudinal direction" or "MD" includes the direction in which fabrics are produced or transported. As used herein, the term "cross direction" or "CD" includes the direction of fabrics substantially perpendicular to the MD.

[0042] As used herein, the term "filler" may include particles or aggregates of particles and other forms of materials that may be added to polymer film blends. According to certain embodiments of the present invention, the filler may not substantially chemically interfere with or adversely affect the extruded film. According to certain embodiments of the present invention, the filler is capable of being uniformly dispersed throughout the film or in a layer contained in a multilayer film. Fillers may include, for example, particulate inorganic materials such as calcium carbonate, various clays, silica, aluminum oxide, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolites, aluminum sulfate, cellulose powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, glass particles, etc., as well as organic particulate materials such as high melting point polymers (e.g., from EI DuPont de Nemours and Company). and ), pulp powder, wood flour, cellulose derivatives, chitin and chitin derivatives, etc. The filler particles can optionally be coated with a fatty acid such as stearic acid or reduced stearic acid, or a larger chain fatty acid such as behenic acid. Without wishing to be bound by theory, according to certain embodiments of the present invention, the coated filler particles can promote free flow of the particles (in the bulk) and their easy dispersion into the polymer matrix.

[0043] Certain embodiments of the present invention provide self-adhesive articles, such as housewrap, comprising (i) a weatherable barrier comprising a first nonwoven fabric attached to a first vapor permeable and liquid impermeable (VPLI) film, (ii) an adhesive layer comprising an adhesive composition, wherein the adhesive layer may be positioned adjacent to the first nonwoven fabric, and wherein the first nonwoven fabric is positioned between the first VPLI film and the adhesive layer; and (iii) a release liner positioned adjacent to the adhesive layer, wherein the adhesive layer is positioned between the first nonwoven fabric and the release liner.

[0044] For example, Figure 1 A self-adhesive article 1 is shown comprising a weather resistant barrier layer 10 comprising a first nonwoven fabric 20 and a first VPLI film 30, the self-adhesive article 1 further comprising a discontinuous adhesive layer 50 deposited on the first nonwoven fabric 20 and a release liner 70 disposed on the adhesive layer 50, Figure 2 Shows something like Figure 1 The self-adhesive article comprises a continuous adhesive layer 51.

[0045] According to certain embodiments of the present invention, the first nonwoven fabric comprises at least one spunbond layer, at least one meltblown layer or any combination thereof. For example, the first nonwoven fabric may include a spunbond nonwoven fabric comprising continuous spunbond fibers from one or more warp beams. The first nonwoven fabric may be consolidated by a thermal bonding operation, such as point bonding or ultrasonic bonding. Although the bond area of ​​the first nonwoven fabric can vary, the bond area may include about 5% to about 30%, such as at least about any of the following: 5, 8, 10, 12 and 15%, and / or at most about any of the following: 30, 28, 25, 22, 20, 18 and 15%. Additionally or alternatively, the first nonwoven fabric comprises at least one polyolefin, such as at least one polypropylene, at least one polyethylene, at least one ethylene-polypropylene impact copolymer or any combination thereof. Additionally or alternatively, the first nonwoven fabric may include polyester and / or polyamide. The fibers (e.g., continuous spunbond fibers) may include monocomponent fibers and / or bicomponent fibers, such as side-by-side or sheath-core bicomponent fibers. The bicomponent fibers, for example, can comprise a first polyolefin forming a first component of the bicomponent fibers and a second polyolefin, polyester, or polyamide forming a second component of the bicomponent fibers. In this regard, the first polyolefin can have a lower melting point relative to the second polyolefin, polyester, or polyamide, such that the first polyolefin can be melted to consolidate the first nonwoven fabric while maintaining the strength associated with the higher melting point component.

[0046] According to certain embodiments of the present invention, the first nonwoven fabric comprises a polymer component containing at least one polyolefin, and optionally comprises an additive component containing one or more additive materials. There are no particular restrictions on the additive material, but can include UV stabilizers, fillers, antimicrobial agents and antistatic agents. The additive component can, for example, account for about 0.1 to about 40% by weight of the first nonwoven fabric, for example, at least about any one of the following: 0.1%, 0.5%, 1%, 3%, 5%, 8% and 10% by weight of the first nonwoven fabric, and / or at most about any one of the following: 40%, 35%, 30%, 25%, 20%, 18%, 15%, 12% and 10% by weight. Additionally or alternatively, the polymer component comprises from about 60% to 100% by weight of the first nonwoven fabric, for example, at least about any of 60%, 70%, and 80% by weight of the first nonwoven fabric, and / or at most about any of 100%, 99%, 98%, 95%, 90%, 85%, and 80% by weight of the first nonwoven fabric. Additionally or alternatively, the polymer component comprises from about 60 to 100% by weight of at least one polypropylene, for example, at least about any of 60%, 70%, and 80% by weight, and / or at most about any of 100%, 99%, 98%, 95%, 90%, 85%, and 80% by weight of the first nonwoven fabric.

[0047] According to certain embodiments of the present invention, the first nonwoven fabric may have a basis weight of about 50 to about 140 gsm, such as at least about any of the following: 50, 60, 70, 80, and 90 gsm, and / or at most about any of the following: 140, 130, 120, 110, 100, and 90 gsm.

[0048] According to certain embodiments of the present invention, the first VPLI may comprise or consist of a single-layer membrane. For example, the single-layer membrane may be a microporous membrane. For example, the microporous membrane may comprise at least one polyolefin, such as at least one polypropylene, at least one propylene-containing copolymer, at least one polyethylene, at least one ethylene-containing copolymer, or any combination thereof. For example, the microporous membrane may include a plurality of filler particles that promote the formation of a plurality of micrometer-sized pores. Alternatively, the single-layer membrane may be a monolithic membrane. The monolithic membrane may comprise at least one highly breathable polymer, such as at least one of a thermoplastic polyurethane, a polyether-block-amide copolymer, a polyether-block-ester copolymer, a polyester-block-amide copolymer, a copolyester thermoplastic elastomer, or a blend thereof. For example, the monolithic membrane may be free of or substantially free of pores.

[0049] According to certain embodiments of the present invention, the first VPLI may include a multilayer membrane comprising at least one microporous layer, at least one integral layer, or a combination thereof. For example, the multilayer membrane may include a plurality of microporous layers (e.g., 2, 3, 4, 5 layers), the plurality of microporous layers comprising a first microporous layer and a second microporous layer, the first microporous layer and the second microporous layer each independently comprising at least one polyolefin, such as at least one polypropylene, at least one propylene-containing copolymer, at least one polyethylene, at least one ethylene-containing copolymer, or any combination thereof. For example, the multilayer membrane may include a first microporous layer that is stronger and more resistant to damage and / or puncture relative to the second microporous layer. In this regard, the first microporous layer may be located at or define the outermost layer of the first VPLI membrane that faces away from the first nonwoven fabric, which outermost layer may be more likely to be exposed to accidental contact with tools and other materials. Thus, the first microporous layer can be used as a sacrificial layer to protect the second microporous layer from damage while maintaining a desired level of air permeability. For example, the multilayer membrane may be composed of a plurality of microporous layers, comprising a first microporous layer and a second microporous layer, wherein the first microporous layer and the second microporous layer each independently comprise at least one polyolefin, such as at least one polypropylene, at least one propylene-containing copolymer, at least one polyethylene, at least one ethylene-containing copolymer, or any combination thereof.

[0050] According to certain embodiments of the present invention, the multilayer film can include a plurality of integral layers (e.g., 2, 3, 4, 5 layers), including a first integral layer and a second integral layer, each of which independently comprises at least one highly breathable polymer, such as at least one of a thermoplastic polyurethane, a polyether-block-amide copolymer, a polyether-block-ester copolymer, a polyester-block-amide copolymer, a copolyester thermoplastic elastomer, or a blend thereof. In a similar manner, the multilayer film can include a first integral layer that is stronger and more resistant to damage and / or puncture relative to the second integral layer. In this regard, the first integral layer can be located at or define the outermost layer of the first VPLI membrane that faces away from the first nonwoven fabric, which outermost layer may be more likely to be exposed to accidental contact with tools and other materials. Thus, the first integral layer can serve as a sacrificial layer to protect the second integral layer from damage while maintaining the desired level of breathability. For example, the multilayer film can be composed of a plurality of integral layers, the plurality of integral layers comprising a first integral layer and a second integral layer, the first integral layer and the second integral layer each independently comprising at least one of a thermoplastic polyurethane, a polyether-block-amide copolymer, a polyether-block-ester copolymer, a polyester-block-amide copolymer, a copolyester thermoplastic elastomer, or a blend thereof. For example, the multilayer film can be composed of a plurality of integral layers, comprising a first integral layer and a second integral layer, the first integral layer and the second integral layer each independently comprising at least one highly breathable polymer, such as at least one of a thermoplastic polyurethane, a polyether-block-amide copolymer, a polyether-block-ester copolymer, a polyester-block-amide copolymer, a copolyester thermoplastic elastomer, or a blend thereof.

[0051] According to certain embodiments of the present invention, a multilayer membrane may include a combination of a microporous layer and a monolithic layer. For example, the microporous layer may be used as a sacrificial layer, as described above for the monolithic layer. The multilayer membrane may include a base layer, a first surface layer, and a second surface layer, wherein the base layer is directly or indirectly located between the first surface layer and the second surface layer. According to certain embodiments of the present invention, at least one of the first surface layer and the second surface layer includes a respective microporous layer, and the base layer includes a monolithic layer.

[0052] According to certain embodiments of the present invention, the first VPLI may have a basis weight of about 10 to about 60 gsm, such as at least about any one of the following: 10, 15, 20, 25, and 30 gsm, and / or at most about any one of the following: 60, 50, 40, and 30 gsm. Additionally or alternatively, the first VPLI may have a thickness of from about 5 mils to about 25 mils, such as at least about any one of the following: 5, 8, 10, 12, and 15 mils, and / or at most about any one of the following: 25, 20, 18, and 15 mils.

[0053] According to certain embodiments of the present invention, the first VPLI can have a hydrostatic pressure resistance of at least about 500 cm according to AATCC 127-1995, such as at least about any of the following: 500, 550, 600, 650, 700, 750, and 800 cm, and / or at most about any of the following: 1500, 1400, 1300, 1200, 1100, 1000, 900, and 800 cm. Additionally or alternatively, the first VPLI can have a moisture vapor transmission rate (MVTR) of at least about 10 US perm to about 60 US perm according to ASTM E96-A, such as at least about any of the following: 10, 12, 15, 18, 20, 25, and 30 US perm, and / or at most about any of the following: 60, 50, 40, and 30 US perm. Additionally or alternatively, the first VPLI can have an air permeability at 75 Pa according to ASTM E2178 of at most about 0.1 L / m2, for example at most about any one of 0.1, 0.08, 0.05, 0.02, and 0.01 L / m2, as measured at 75 Pa according to ASTM E2178.

[0054] For example, the first VPLI film can be melt-extruded directly onto the first nonwoven fabric. In this regard, the first VPLI film can be directly bonded to the first nonwoven fabric without the need for an adhesive composition located therebetween. The first VPLI film can, for example, at least partially penetrate into the first nonwoven fabric.

[0055] According to certain embodiments of the present invention, adhesive layer may include a discontinuous layer of adhesive composition, wherein the discontinuous layer has one or more regions that do not contain adhesive composition.For example, the discontinuous layer of adhesive composition may include a plurality of discrete regions of adhesive composition, and the discrete regions are surrounded by the continuous region that does not contain adhesive composition. Alternatively, the discontinuous layer of adhesive composition may include a plurality of discrete regions of the adhesive composition provided in an alternating manner and a plurality of discrete regions that do not contain adhesive composition. A plurality of discrete regions of adhesive composition can define adhesive region on the first nonwoven fabric, and the adhesive region is approximately 20% to approximately 80% of the first surface of the first nonwoven fabric, for example, at least about any one of the following: 20, 25, 30, 35 and 40%, and / or at most about any one of the following: 80, 75, 70, 65, 60, 55, 50, 45 and 40%.

[0056] According to certain embodiments of the present invention, the first nonwoven fabric has a first end and a second end in a transverse direction, and wherein the plurality of discrete areas of the adhesive composition include a first discrete area of ​​the adhesive composition at or adjacent to the first end, a second discrete area of ​​the adhesive composition at or adjacent to the first end, and a plurality of intermediate discrete areas of the adhesive composition between the first discrete area of ​​the adhesive composition and the second discrete area of ​​the adhesive composition. The first discrete area of ​​the adhesive composition defines a first coating area, the second first discrete area of ​​the adhesive composition defines a second coating area, and the plurality of intermediate discrete areas of the adhesive composition have an average intermediate coating area, and wherein the first coating area and / or the second coating area is greater than the average intermediate coating area. Additionally or alternatively, the discontinuous adhesive layer may comprise a first ratio between the first coating area and the average intermediate coating area of ​​about 2.5:1 to about 10:1, such as at least about any of the following: 2.5:1, 3:1, 3.5:1, 4:1, 4.5:1, 5:1, and 5.5:1, and / or at most about any of the following: 10:1, 9:1, 8:1, 7:1; 6:1, and 5.5:1. Additionally or alternatively, the discontinuous adhesive layer may comprise a second ratio between the second coating area and the average intermediate coating area of ​​about 2.5:1 to about 10:1, such as at least about any of the following: 2.5:1, 3:1, 3.5:1, 4:1, 4.5:1, 5:1, and 5.5:1, and / or at most about any of the following: 10:1, 9:1, 8:1, 7:1; 6:1, and 5.5:1. Additionally or alternatively, the discontinuous adhesive layer may comprise a third ratio between (i) the total intermediate coating area comprising the sum of the plurality of intermediate discrete regions of the adhesive composition and (ii) the sum of the first coating area and the second coating area of ​​from about 2:1 to about 5:1, e.g., at least about any of 2:1, 2.2:1, 2.5:1, 2.8:1, 3:1, 3.2:1, and 3.5:1, and / or at most about any of 5:1, 4.8:1, 4.5:1, 4.2:1, 4:1, 3.8:1, and 3.5:1.

[0057] According to certain embodiments of the present invention, the plurality of discrete areas of the adhesive composition may comprise a straight line, a curved line (e.g., a wave, a circle, an S-shape, etc.), or a combination thereof. Additionally or alternatively, the straight line, the curved line, or a combination thereof extends along the longitudinal direction or the transverse direction of the first nonwoven fabric.

[0058] For example, Figure 3Shown are a discontinuous adhesive layer 50 according to some embodiments of the present invention, a plurality of discrete areas of adhesive composition, and a plurality of discrete areas without any adhesive composition. The plurality of discrete areas of adhesive composition include a first discrete area 54 of adhesive composition at or near the first end of the first nonwoven fabric, a second discrete area 56 of adhesive composition at or near the second end of the first nonwoven fabric, and a plurality of intermediate discrete areas 58 of adhesive composition between the first discrete area of ​​adhesive composition and the second discrete area of ​​adhesive composition. Each discrete area without any adhesive composition 67 in the plurality of discrete areas is positioned in an alternating manner with the plurality of intermediate discrete areas 58 of adhesive composition. Figure 4 Another discontinuous adhesive layer 50 according to some embodiments of the present invention is shown including a continuous region 68 devoid of any adhesive composition. Figure 5 Another discontinuous adhesive layer 50 according to some embodiments of the present invention is shown including a continuous region 68 devoid of any adhesive composition.

[0059] According to certain embodiments of the present invention, the discontinuous layer of adhesive composition comprises a continuous network of adhesive composition and a plurality of discrete islands without adhesive composition, wherein the plurality of discrete islands are surrounded by the continuous network of adhesive composition. For example, Figure 6 A discontinuous adhesive layer 50 according to certain embodiments of the present invention is shown comprising a plurality of individual islands 69 devoid of any adhesive composition, the islands being surrounded by a network of adhesive composition 62. According to certain embodiments of the present invention, the continuous network of adhesive composition defines an adhesive area on the first nonwoven fabric of from about 20% to about 80% of the first surface of the first nonwoven fabric, such as at least about any of 20, 25, 30, 35, and 40%, and / or at most about any of 80, 75, 70, 65, 60, 55, 50, 45, and 40%.

[0060] Figure 7 Another discontinuous adhesive layer 50 according to certain embodiments of the present invention is shown that includes a continuous area 68 without any adhesive composition. The discontinuous adhesive layer 50 includes a first discrete area 54 of adhesive composition at or near the first end of the first nonwoven fabric, a second discrete area 56 of adhesive composition at or near the second end of the first nonwoven fabric, and a plurality of intermediate discrete areas 58 of adhesive composition located between the first discrete area of ​​adhesive composition and the second discrete area of ​​adhesive composition. The plurality of intermediate discrete areas 58 of adhesive composition are surrounded by the continuous area 68 without any adhesive composition.

[0061] According to certain embodiments of the present invention, the adhesive layer may comprise a continuous layer of an adhesive composition. In this regard, the entire first nonwoven fabric facing away from the first VPLI membrane may be coated with the adhesive composition. In such embodiments, it may be desirable to use a thinner coating of the adhesive composition and / or select an adhesive composition that is breathable to allow water vapor to pass therethrough.

[0062] According to certain embodiments of the present invention, the adhesive layer, whether discontinuous or continuous, can have a basis weight of from about 0.5 to about 5 gsm, such as at least about any of the following: 0.5, 0.8, 1, 1.2, 1.5, 1.8, 2, 2.2, and 2.5 gsm, and / or at most about any of the following: 5, 4.8, 4.5, 4.2, 4, 3.8, 3.5, 3.2, 3, 2.8, and 2.5 gsm. Additionally or alternatively, the adhesive composition is breathable and allows water vapor to at least partially pass therethrough.

[0063] According to certain embodiments of the present invention, the adhesive composition comprises a hot melt adhesive, such as ethylene-vinyl acetate copolymer; styrene-isoprene-styrene copolymer; styrene-butadiene-styrene copolymer; ethylene ethyl acrylate copolymer; and polyurethane reactive butyl or halogenated butyl rubber, acrylic acid, ethylene propylene rubber (EPR), ethylene propylene diene monomer (EPDM) or styrene / butadiene rubber (SBR) and styrene-butylene-styrene copolymer. Additionally or alternatively, the adhesive composition may particularly include a rubber adhesive, such as a hot melt rubber adhesive composition and / or a solvent-based rubber adhesive composition. Additionally or alternatively, the adhesive composition comprises a pressure-sensitive adhesive, which may include (meth) acrylic acid homopolymers and copolymers, such as isooctyl acrylate, 2-ethylhexyl acrylate. For example, some exemplary adhesive compositions may include commercially available adhesives from Bostik, Inc. (Wauwatosa, Wisconsin, USA). 2211, commercially available from Bostik, Inc. (Wauwatosa, Wisconsin, USA) 2571, commercially available from Henkel (Düsseldorf, Germany) PS1581NA, 321-H commercially available from Hero Coatings (Newburyport, MA), and 915 commercially available from Hero Coatings (Newburyport, MA). Additionally or alternatively, the adhesive composition comprises a solvent-based acrylic adhesive. For example, some exemplary adhesive compositions may include Aroset commercially available from Bostik, Inc. (Wauwatosa, Wisconsin, USA). TM S488, Aroset commercially available from Bostik, Inc. (Wauwatosa, Wisconsin, USA) TM 1085, Durotack DT AH 115 commercially available from Henkel (Düsseldorf, Germany), Durotack DT 151A commercially available from Henkel (Düsseldorf, Germany), S8730T commercially available from Avery Dennison (Mill Hall, PA), S8655 commercially available from Avery Dennison (Mill Hall, PA), all commercially available from Toyo Ink (Tokyo, Japan), BPS6080 and STS0122.

[0064] According to certain embodiments of the present invention, the adhesive composition may, for example, have certain ranges of various properties, including any of the properties provided in Table 1 below:

[0065]

[0066] Table 1

[0067] According to certain embodiments of the present invention, the release liner comprises a release surface located near the adhesive layer, wherein the release liner comprises a film or a paper sheet. For example, the release surface comprises a low surface energy release surface coating, such as silicone, siloxane, fluoropolymer, and polyurethane. In this regard, the bond strength between the adhesive layer and the release liner is less than the bond strength between the adhesive layer and the first nonwoven fabric. Like this, before being mounted on the desired surface, the release liner can be peeled off from the self-adhesive article to expose the adhesive layer.

[0068] According to certain embodiments of the present invention, the self-adhesive article may further include a three-dimensional, non-uniform, or discontinuous meltblown layer located on the outer surface of the first VPLI film. The meltblown layer may include meltblown streams, meltblown ropes, or both, wherein the meltblown streams, meltblown ropes, or both are randomly and irregularly distributed on the outer surface of the first VPLI film. For example, Figure 8 A top view of a self-adhesive article according to an exemplary embodiment is shown, comprising a plurality of meltblown streams and meltblown ropes deposited on a side of a first VPLI film facing away from a first nonwoven fabric. For example, Figure 9 1 shows a side view of a meltblown stream and a meltblown rope deposited onto a first VPLI according to an embodiment of the present invention. Figure 8 and Figure 9 As shown, for example, the discontinuous meltblown layer 110 has a plurality of three-dimensional protrusions in the form of meltblown ropes 115 and meltblown beads 120. Figure 8 and Figure 9 As shown, the meltblown rope 115 and the meltblown stream 120 are generally isolated from each other (e.g., a discontinuous meltblown layer). In this regard, a continuous air gap 125 may be formed between the meltblown rope 115 and / or the meltblown stream 120. For example, Figure 9 A side view illustrating the formation of a continuous air gap 125 is shown. Figure 8 and Figure 9 A non-continuous meltblown layer is shown, but certain embodiments of the present invention may include a non-uniform meltblown layer rather than a non-continuous meltblown layer as disclosed herein. In such embodiments, for example, the non-uniform meltblown layer may include individual meltblown streams and / or meltblown ropes that are integrated within a continuous layer of interconnected meltblown fibers and that substantially cover or cover the entire surface of the first VPLI film that faces away from the first nonwoven fabric.

[0069] According to certain embodiments of the present invention, the self-adhesive article comprises a drainage efficiency according to ASTM E2273 of about 90% to about 100%, for example, at least about 90, 92, 94, and 95%, and / or at most about any of the following: 100, 99, 98, 96, and 95%. Additionally or alternatively, the three-dimensional, non-uniform, or discontinuous meltblown layer comprises at least one of polypropylene, an ethylene-propylene impact copolymer blend, or any combination thereof. For example, the meltblown shot may comprise irregularly shaped fibers, fillers, or particles. Additionally or alternatively, the three-dimensional, non-uniform, or discontinuous meltblown layer comprises an average shot height, rope height, or both, from about 0.1 mm to about 1.0 mm, such as at least about any of the following: 0.1, 0.2, 0.3, 0.4, and 0.5 mm, and / or at most about any of the following: 1, 0.9, 0.8, 0.7, 0.6, and 0.5 mm. Additionally or alternatively, the three-dimensional, non-uniform, or discontinuous meltblown layer can comprise a basis weight of about 1 gsm to about 20 gsm, e.g., at least about any of 1, 2, 3, 5, 8, and 10 gsm, and / or at most about any of 20, 18, 15, 12, and 10 gsm.

[0070] According to certain embodiments of the present invention, the weather resistant barrier layer has a basis weight of from about 60 to about 250 gsm, for example, at least about any of 60, 70, 80, 90, 100, 110, 120, 130, 140, and 150 gsm, and / or at most about any of 250, 220, 200, 180, 160, and 150 gsm. Additionally or alternatively, the weather resistant barrier layer has a thickness of from about 8 to about 30 mils, for example, at least about any of 8, 10, 12, 15, 18, and 20 mils, and / or at most about any of 20, 22, 24, 25, 26, 28, and 30 mils.

[0071] According to certain embodiments of the present invention, the weatherable barrier layer has a hydrostatic pressure resistance of at least about 500 cm according to AATCC 127-1995, for example, at least about any of the following: 500, 550, 600, 650, 700, 750, and 800 cm, and / or at most about any of the following: 1500, 1400, 1300, 1200, 1100, 1000, 900, and 800 cm. Additionally or alternatively, the weatherable barrier layer has a moisture vapor transmission rate (MVTR) of at least about 10 US perm to about 60 US perm according to ASTM E96-A, for example, at least about any of the following: 10, 12, 15, 18, 20, 25, and 30 US perm, and / or at most about any of the following: 60, 50, 40, and 30 US perm. Additionally or alternatively, the weatherable barrier layer has an air permeability of at most about 0.1 L / m2 at 75 Pa according to ASTM E2178, for example at most about any of the following: 0.1, 0.08, 0.05, 0.02, and 0.01 L / m2 at 75 Pa according to ASTM E2178.

[0072] According to certain embodiments of the present invention, the weatherable barrier layer has a peel adhesion to oriented strand board (OSB) of at least about 1.5 lb / inch according to ASTM D3330 Method F (20 minute and 24 hour dwell times), such as at least about 1.5, 1.8, 2, 2.5, 2.8, and 3 lb / inch, and / or at most about any of 6, 5.5, 5, 4.5, 4, 3.5, and 3 lb / inch. Additionally or alternatively, the weatherable barrier layer has a peel adhesion to anodized aluminum of at least about 1.5 lb / inch according to ASTM D3330 Method F (20 minute and 24 hour dwell times), such as at least about 1.5, 1.8, 2, 2.5, 2.8, and 3 lb / inch, and / or at most about any of 6, 5.5, 5, 4.5, 4, 3.5, and 3 lb / inch. Additionally or alternatively, the weatherable barrier layer has a peel adhesion to vinyl according to ASTM D3330 Method F (20 minutes and 24 hours dwell time) of at least about 1.5 lbs / inch, such as at least about 1.5, 1.8, 2, 2.5, 2.8, and 3 lbs / inch, and / or at most about any of 6, 5.5, 5, 4.5, 4, 3.5, and 3 lbs / inch. Additionally or alternatively, the weatherable barrier layer has a plywood peel adhesion (APA Grade Exposure 1) according to ASTM D3330 Method F (20 minutes and 24 hours dwell time) of at least about 1.5 lbs / inch, such as at least about 1.5, 1.8, 2, 2.5, 2.8, and 3 lbs / inch, and / or at most about any of 6, 5.5, 5, 4.5, 4, 3.5, and 3 lbs / inch.

[0073] According to certain embodiments of the present invention, the weather-resistant barrier layer has a machine direction trapezoidal tear resistance of about 25 to about 40 pounds according to ASTM D5733, for example, at least about any one of the following: 25, 26, 28 and 30 pounds, and / or at most about any one of the following: 40, 38, 36, 35, 34, 32 and 30 pounds. Additionally or alternatively, the weather-resistant barrier layer has a transverse direction trapezoidal tear resistance of about 25 to about 40 pounds according to ASTM D5733, for example, at least about any one of the following: 25, 26, 28 and 30 pounds, and / or at most about any one of the following: 40, 38, 36, 35, 34, 32 and 30 pounds. Additionally or alternatively, the weather-resistant barrier layer has a machine direction breaking strength of about 25 to about 40 pounds according to ASTM D5733, for example, at least about any one of the following: 25, 26, 28 and 30 pounds, and / or at most about any one of the following: 40, 38, 36, 35, 34, 32 and 30 pounds. The D5034 is about 50 to about 80 pounds, for example, at least about any one of 50, 52, 55, 58, 60, 62, 65, and 68 pounds, and / or at most about any one of 80, 78, 75, 72, 70, and 68 pounds. Additionally or alternatively, the weatherable barrier layer has a transverse direction breaking strength according to ASTM D5034 of about 50 to about 80 pounds, for example, at least about any one of 50, 52, 55, 58, 60, 62, 65, and 68 pounds, and / or at most about any one of 80, 78, 75, 72, 70, and 68 pounds.

[0074] According to certain embodiments of the present invention, the weather-resistant barrier layer has a Glihill porosity of about 2500 s / 100 cc to about 5000 s / 100 cc, for example, at least about any of the following: 2500, 2800, 3000, 3200 and 3500 s / 100 cc, and / or at most about any of the following: 5000, 4800, 4500, 4200, 4000, 3800 and 3500 s / 100 cc.

[0075] According to certain embodiments of the present invention, the self-adhesive article comprises a width of about 3 feet to about 10 feet, such as at least about any of 4, 5, and 6 feet, and / or at most about any of 10, 8, and 6 feet.

[0076] In another aspect, certain embodiments of the present invention provide a method for preparing a self-adhesive article, such as a housewrap material. The method can include the following steps: (i) melt-extruding a first vapor-permeable and liquid-impermeable (VPLI) film directly onto a first surface of a first nonwoven fabric to form a weatherable barrier layer or providing a weatherable barrier layer comprising a first VPLI film melt-extruded onto a first nonwoven fabric; (ii) depositing an adhesive layer comprising an adhesive composition directly onto a second surface of the first nonwoven fabric, wherein the first nonwoven fabric is located between the first VPLI film and the adhesive layer; and (iii) applying a release liner to and in contact with the adhesive layer, wherein the adhesive layer is located between the first nonwoven fabric and the release liner to form a self-adhesive article.

[0077] According to certain embodiments of the present invention, the step of depositing the adhesive layer may include a die coating operation (e.g., a slot die coating operation), a spray coating operation, a knife coating operation, or any combination thereof. The deposition of the adhesive layer may impart a continuous or discontinuous adhesive layer, such as those described and disclosed herein, on a first nonwoven fabric having various thicknesses, for example. Additionally or alternatively, the method may further include depositing a three-dimensional, non-uniform, or discontinuous meltblown layer on the outer surface of the first VPLI membrane, the meltblown layer comprising meltblown streams, meltblown ropes, or both. In this regard, the meltblown streams, meltblown ropes, or both may be randomly and irregularly distributed on the outer surface of the first VPLI membrane.

[0078] In another aspect, certain embodiments of the present invention provide building assemblies, wherein the building assemblies can include interior covering members, exterior building materials, and self-adhesive articles, such as those described and disclosed herein, wherein the release liner has been peeled (e.g., peeled) and the adhesive layer bonds the weatherable barrier layer to the interior covering members.

[0079] According to certain embodiments of the present invention, a self-adhesive article may include a three-dimensional, non-uniform, or discontinuous meltblown layer located on, for example, the outer surface of a first VPLI film. The meltblown layer may include meltblown streams, meltblown ropes, or both. The meltblown streams, meltblown ropes, or both may be randomly and irregularly distributed on, for example, the outer surface of the first VPLI film. In this case, for example, the meltblown streams, meltblown ropes, or a combination thereof may define a continuous air gap between the weatherable barrier layer and the exterior building material, which air gap enables multi-directional flow of liquid along the outer surface of the first VPLI film. The continuous air gap may include a height corresponding to the average shot height, rope height, or both.

[0080] For example, Figure 10 1 shows a cross-sectional side view of a building assembly according to some embodiments of the present invention. Figure 10As shown, for example, building assembly 305 includes an interior cover member 340 secured to support columns 350. In some embodiments of the present invention, for example, interior cover member 340 can be formed from panels of plywood, oriented strand board, particle board, insulated concrete, or any other material permitted by local building codes. During construction of building assembly 305, self-adhesive article 300 can have its release liner removed to expose the adhesive layer and be adhesively secured to interior cover member 340 such that weatherable barrier layer 310 completely covers interior cover member 340 and the first VPLI film faces away from interior cover member 340. In embodiments including a meltblown rope layer and / or meltblown stream 320 disposed on the first VPLI film, the meltblown rope layer and / or meltblown stream faces away from interior cover member 340. In some embodiments of the present invention, for example, self-adhesive article 300 can be secured to interior cover member 340 without the use of staples or the like. Self-adhesive article 300 can extend horizontally or vertically within building assembly 305. Several slightly overlapping rows of self-adhesive articles 300 extending horizontally or vertically are required to cover the entire height of building assembly 305. In this regard, the continuous ventilation path P formed by the meltblown rope and / or meltjet stream 320, if present, can allow moisture to vent downward along the meltblown rope and / or meltjet stream 320 within building assembly 305. Exterior building material 330 can be secured to the exterior of building assembly 305 so that it covers self-adhesive article 300 and sandwiches self-adhesive article 300 between interior covering member 340 and exterior building material 330. In some embodiments of the present invention, for example, exterior building material 330 can be a wood or fiber cement siding product or shingles, such as cedar shingles. Exterior building material 330 can also be brick, stone, stucco, exterior insulation finish system (EIFS), vinyl, metal, asphalt, rubber, thermoplastics, and other suitable exterior siding and roofing materials. In this regard, building assembly 305 can be an exterior wall of a building, an exterior roof of a building, and / or the like.

[0081] For example, Figure 11 The embodiment of the present invention is shown Figure 10 Part of the building assembly shown. Figure 11As shown, for example, meltblown ropes and / or meltblown streams 320 can be irregularly spaced across the weather-resistant barrier 310 such that continuous air gaps 325 can be formed between the exterior building material and the weather-resistant barrier 310. In this regard, the continuous air gaps 325 can provide drainage and ventilation paths P within the building assembly 305. Any moisture that collects within the building assembly 305 can be provided with a path to drain downwardly from the building assembly 305 under the action of gravity. The plurality of continuous air gaps 325 dispersed throughout the building assembly 305 can also enable air to circulate between the inner sheathing member 340 and the exterior building material 330 to aid in drying or evaporating any moisture present in the building assembly 305.

[0082] Example

[0083] The present disclosure is further illustrated by the following examples, which should in no way be construed as limiting. That is, the specific features described in the following examples are merely illustrative and not limiting.

[0084] Exemplary fabric laminate structure for adhesive area coating:

[0085] According to certain exemplary embodiments, a breathable film (eg, a weatherable barrier) is produced that includes a film having a viscosity of 1.5 to 2.5 oz / yd 2 The adhesive layer is applied in a first layer of a polypropylene nonwoven fabric having a basis weight of 25-50 gsm, and a second layer comprising a multilayer VPLI film (e.g., a PP / PE / PP multilayer-breathable VPLI film) having a basis weight of 25-50 gsm. The general pattern of the adhesive layer can be described as applying alternating continuous dry (e.g., areas without adhesive composition) and wet (e.g., areas with adhesive composition) zones in the machine direction: the dry zones (e.g., areas without adhesive composition) can have a width of 1 / 16" to 6" wide, and the wet zones (e.g., areas with adhesive composition) can have a width of 1 / 16" to 6" wide. The widths of the dry and wet zones can be or can be arranged in a repeating or non-repeating pattern, such as those described and disclosed herein. Table 2 summarizes the peel strength after low temperature exposure.

[0086] However, according to certain embodiments of the present invention, the first layer (eg, nonwoven fabric) may be at a pressure of 0.9 to 10 oz / yd 2 The first layer (eg, VPLI film) may be in the range of 30 to 340 gsm, the second layer (eg, VPLI film) may be in the range of 15 to 55 gsm, and the total basis weight may be in the range of 45 to 395 gsm (eg, 70-150 gsm or 75-120 gsm).

[0087] Table 2

[0088]

[0089]

[0090] Table 2

[0091] These and other modifications and variations may be made to the present invention by those skilled in the art without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchangeable in whole or in part. Furthermore, it will be understood by those skilled in the art that the foregoing description is merely exemplary and is not intended to limit the present invention as further described in these appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.

Claims

1. A self-adhesive product comprising: (i) a weatherable barrier comprising a first nonwoven fabric attached to a first vapor permeable and liquid impermeable (VPLI) film; (ii) an adhesive layer comprising an adhesive composition, the adhesive layer being adjacent to the first nonwoven fabric, wherein the first nonwoven fabric is positioned between the first VPLI film and the adhesive layer; (iii) a release liner disposed adjacent to the adhesive layer, wherein the adhesive layer is located between the first nonwoven fabric and the release liner.

2. The self-adhesive article of claim 1, wherein the first nonwoven fabric comprises at least one spunbond layer, at least one meltblown layer, or any combination thereof.

3. The self-adhesive article according to claims 1-2, wherein the first VPLI film comprises a single layer film, wherein the single layer film is a microporous film or a monolithic film.

4. The self-adhesive article of claims 1-2, wherein the first VPLI film comprises a multilayer film comprising at least one microporous layer, at least one monolithic layer, or a combination thereof.

5. The self-adhesive article of claim 4, wherein the multilayer film comprises a plurality of microporous layers, the plurality of microporous layers comprising a first microporous layer and a second microporous layer, the first microporous layer and the second microporous layer each independently comprising at least one polyolefin, at least one propylene-containing copolymer, at least one polyethylene, at least one ethylene-containing copolymer, or any combination thereof.

6. The self-adhesive article of claim 4, wherein the multilayer film comprises a plurality of integral layers, the plurality of integral layers comprising a first integral layer and a second integral layer, the first integral layer and the second integral layer each independently comprising at least one highly breathable polymer, the highly breathable polymer comprising at least one of a thermoplastic polyurethane, a polyether block amide copolymer, a polyether block ester copolymer, a polyester block amide copolymer, a copolyester thermoplastic elastomer, or a blend thereof.

7. The self-adhesive article of claims 1-6, wherein the first VPLI film has a basis weight of about 10 gsm to about 60 gsm, a thickness of about 5 mils to about 25 mils, or both.

8. The self-adhesive article of claims 1-7, wherein the first VPLI film is melt extruded directly onto the first nonwoven fabric.

9. The self-adhesive article of claims 1-8, wherein the adhesive layer comprises a discontinuous layer of the adhesive composition, wherein the discontinuous layer of the adhesive composition comprises a plurality of discrete areas of the adhesive composition surrounded by continuous areas free of the adhesive composition.

10. The self-adhesive article of claim 9, wherein the first nonwoven fabric has a first end and a second end in a transverse direction, and wherein the plurality of discrete areas of the adhesive composition include a first discrete area of ​​the adhesive composition at or adjacent the first end, a second discrete area of ​​the adhesive composition at or adjacent the first end, and a plurality of intermediate discrete areas of the adhesive composition located between the first discrete area of ​​the adhesive composition and the second discrete area of ​​the adhesive composition; wherein the first discrete area of ​​the adhesive composition defines a first coating area, the second first discrete area of ​​the adhesive composition defines a second coating area, and the plurality of intermediate discrete areas of the adhesive composition have an average intermediate coating area, and wherein the first coating area and / or the second coating area is greater than the average intermediate coating area.

11. The self-adhesive article of claim 10, further comprising (i) a first ratio between the first coating area and the average intermediate coating area of ​​from about 2.5:1 to about 10:1, (ii) a third ratio between (a) a total intermediate coating area including the sum of the plurality of intermediate discrete regions of the adhesive composition and (b) the sum of the first coating area and the second coating area of ​​from about 2:1 to about 5:1, or (iii) both (i) and (ii).

12. The self-adhesive article of claims 1-11, further comprising a three-dimensional, non-uniform, or discontinuous meltblown layer positioned on the outer surface of the first VPLI film, the meltblown layer comprising meltblown streams, meltblown ropes, or both; wherein the meltblown streams, the meltblown ropes, or both are randomly and irregularly distributed on the outer surface of the first VPLI film.

13. A method of making a self-adhesive article, the method comprising: (i) melt-extruding a first vapor permeable and liquid impermeable (VPLI) film directly onto a first surface of a first nonwoven fabric to form a weatherable barrier; (ii) depositing an adhesive layer comprising an adhesive composition directly onto the second surface of the first nonwoven fabric, wherein the first nonwoven fabric is positioned between the first VPLI film and the adhesive layer; (iii) applying a release liner onto and in contact with the adhesive layer, wherein the adhesive layer is located between the first nonwoven fabric and the release liner to form a self-adhesive article.

14. The method of claim 13, wherein the step of depositing the adhesive layer comprises a die coating operation, a spray coating operation, a doctor blade coating operation, or any combination thereof.

15. The method of claims 13-14, further comprising depositing a three-dimensional, non-uniform, or discontinuous meltblown layer disposed on the outer surface of the first VPLI film, the meltblown layer comprising meltblown streams, meltblown ropes, or both; wherein the meltblown streams, the meltblown ropes, or both are randomly and irregularly distributed on the outer surface of the first VPLI film.

Images